17730-287 Rev A, Technical Procedure HUV 270t for Dongfeng

Transcription

瀚瑞森 HUV™ 270t Heavy-duty
Rubber Suspension for Dongfeng
Commercial Vehicle (DFCV)
SUBJECT: Service Instructions
LIT NO.: 17730-287
DATE: June 2015
REVISION: A
TABLE OF CONTENTS
Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . 2
Section 7 Alignment & Adjustments . . . . . . . . 21
Section 2 Product Description . . . . . . . . . . . . . . 2
Section 8 Component Replacement . . . . . . . . 22
Section 3 Important Safety Notice. . . . . . . . . . . 4
Section 4 Parts Lists. . . . . . . . . . . . . . . . . . . . . . . 8
Fasteners . . . . . . . . . . . . . . . . . . . . . . . 22
Frame Hanger Assembly. . . . . . . . . . . . 22
Progressive Rate Spring and Spacer . . . 24
Saddle . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section 5 Special Tools . . . . . . . . . . . . . . . . . . . 12
Section 6 Preventive Maintenance. . . . . . . . . .13
Inspection Intervals. . . . . . . . . . . . . . . . 13
Component Inspection . . . . . . . . . . . . . 14
Equalizing Beam End Connection. . . . . 14
Center Bushing. . . . . . . . . . . . . . . . . . . 16
Frame Hanger Assembly . . . . . . . . . . . . 16
Progressive Rate Springs. . . . . . . . . . . . 17
Saddle Cap Bolt Fasteners . . . . . . . . . . 18
Cross Tube . . . . . . . . . . . . . . . . . . . . . . 19
Axle Brackets. . . . . . . . . . . . . . . . . . . . . 19
V‑Torque Rods . . . . . . . . . . . . . . . . . . . 20
Equalizing Beam. . . . . . . . . . . . . . . . . . 27
Center Bushing. . . . . . . . . . . . . . . . . . . 29
Bar Pin End Bushings . . . . . . . . . . . . . . 30
Cross Tube . . . . . . . . . . . . . . . . . . . . . . 33
Section 9 Torque Specifications. . . . . . . . . . . . 34
Section 10 Troubleshooting Guide. . . . . . . . . . . 36
瀚瑞森 HUV™ 270t for DFCV
SECTION 1
Introduction
This publication is intended to acquaint and assist maintenance personnel in the
preventive maintenance, service, repair, and rebuild of the 瀚瑞森 HUV™ 270t suspension
systems for applicable Dongfeng Commercial Vehicles (DFCV).
NOTE
Use only Hendrickson Genuine parts for servicing this suspension system.
It is important to read and understand the entire Technical Procedure publication prior
to p erforming any maintenance, service, repair, or rebuild of this product. The informa‑
tion in this publication contains parts lists, safety information, product specifications,
features, proper maintenance, service, repair and rebuild instructions for the 瀚瑞森
HUV 270t suspensions.
Hendrickson reserves the right to make changes and improvements to its products and
publications at any time. Contact Hendrickson China for information on the latest version
of this manual.
The latest revision of this publication is also available online at
www.hendrickson‑intl.com.cn
SECTION 2
Product Description
瀚瑞森 HUV 270t is a heavy-duty rubber vocational suspension designed for durabil‑
ity, weight savings, and outstanding ride quality. Designed for heavy‑duty applications,
瀚瑞森 HUV 270t offers a considerable weight savings versus competitive suspensions for
increased payload. The system offers a unique balance of superior ride quality and increas‑
ing roll stiffness as the load increases. Rubber shear springs carry a majority of the vertical
load in the empty condition, resulting in a soft ride. As the load increases, the progressive rate
springs deflect more to carry a greater proportion of the load, increasing the stiffness of the
suspension without causing an abrupt change in ride characteristics.
■■
Equalizing beams — Distribute load equally between axles to improve stability and
handling. Offer up to 445 mm of diagonal articulation for outstanding mobility and
traction.
■■
Saddle — Lightweight design helps to increase payload, while offering a considerable
weight savings versus competitive suspensions.
■■
Frame hangers — Optimized design to balance durability and weight savings.
■■
Rubber shear springs — Primary springs in unloaded condition, providing superb
ride quality. React to longitudinal loads during braking and accelerating for minimal
displacement.
■■
Progressive rate springs — Designed to balance empty ride quality and loaded stabil‑
ity. Stiffness of progressive rate spring increases as load increases, providing a unique
balance of empty ride quality and loaded stability.
REDUCED MAINTENANCE
Reduce maintenance costs and help increase uptime of your vehicle:
Introduction
■■
Superior ride results in reduced road shock and vibration to the vehicle, which contrib‑
utes to longer service life of the cab, chassis and body equipment
■■
No lubrication requirements
■■
Rubber shear springs remain in constant compression for long component life
■■
Rubber progressive rate springs provide long service life and easy replacement
■■
Bar pin end bushings extend service life and reduce end bushing replacement time
2
17730-287
FIGURE 2-1
瀚瑞森 HUV 270t SPECIFICATIONS
瀚瑞森 HUV 270t
Capacity
Installed Weight
27 metric tonnes – maximum static loading
460 kg
1
Ride Height
249 mm
Ground Clearance2
200 mm
Axle Spacing
1,400 mm
Axle Configuration
8 x 4 chassis
Axle Travel3
200 mm
Diagonal Articulation4
445 mm
GCW Approval
70 metric tonnes maximum
Lift Axles
Approved
Engine Torque Restrictions
None
1. Suspension weight does not include V-torque rods, V-torque rod axle brackets, V-torque rod frame brackets or beam
attachment brackets. Published weight is for 瀚瑞森 HUV 270t suspension using 252 mm ride height. Other con‑
figurations may change weight.
2. Ground clearance using a 520 mm Static Loaded Radius (SLR) tire is for the standard 瀚瑞森 HUV 270t suspension
with 252 mm ride height. Other configurations may change ground clearance. For different options, please contact
Hendrickson China, your vehicle manufacturer or authorized vehicle dealer for further information.
3. Axle travel may be limited by vehicle manufacturer; axle stop settings may restrict suspension’s articulation. Varying
ride heights and configurations may restrict travel. For different ride height options, please contact Hendrickson
China, your vehicle manufacturer or authorized vehicle dealer for further information.
4. Suspension articulation may exceed vehicle’s capability and may be limited by vehicle manufacturer; vehicle manu‑
facturer installed axle stops may restrict suspension’s articulation.
All Hendrickson 瀚瑞森 HUV 270t suspension applications must comply with applicable Hendrickson specifica‑
tions and must also be approved by the respective vehicle manufacturer with the vehicle in its original, as-built
configuration. Contact Hendrickson China and the respective vehicle manufacturer with any questions regarding
specific applications.
U.S., China and other foreign patents granted and / or pending.
17730-287
3
Product Description
SECTION 3
Important Safety Notice
Proper maintenance, service and repair are important to the reliable operation of the sus‑
pension. 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 dam‑
age 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.
■■ Explanation of signal words
Hazard “Signal Words” (Danger • Warning • Caution) appear in various locations through‑
out 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.
NOTE
An operating procedure, practice condition, etc. which is essential to emphasize.
SERVICE HINT
A helpful suggestion that 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 spe‑
cific purposes.These special tools can be found in the “Special Tools” Section of this publication.
The torque symbol alerts you to tighten the fasteners to a specific torque value. See Torque
Specifications Section of this publication.
4
17730-287
■■ SAFETY PRECAUTIONS
FASTENERS
DISCARD USED FASTENERS. ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR. FAILURE TO
DO SO COULD RESULT IN FAILURE OF THE PART, OR MATING COMPONENTS, LOSS OF VEHICLE
CONTROL, PERSONAL INJURY, OR PROPERTY DAMAGE.
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,
USING A REGULARLY CALIBRATED TORQUE WRENCH. TORQUE VALUES SPECIFIED IN THIS
TECHNICAL PUBLICATION ARE FOR HENDRICKSON SUPPLIED FASTENERS ONLY. IF NON
HENDRICKSON FASTENERS ARE USED, FOLLOW TORQUE SPECIFICATION LISTED IN THE VEHICLE
MANUFACTURER’S SERVICE MANUAL.
TORCH/WELDING
DO NOT USE A CUTTING TORCH TO REMOVE ANY FASTENERS OR BUSHINGS. 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
EQUALIZING BEAM. DO NOT CONNECT ARC WELDING GROUND LINE TO THE EQUALIZING BEAM.
DO NOT STRIKE AN ARC WITH THE ELECTRODE ON THE EQUALIZING BEAM AND AXLE. DO NOT USE
HEAT NEAR THE EQUALIZING BEAM ASSEMBLY. DO NOT NICK OR GOUGE THE EQUALIZING BEAM.
SUCH IMPROPER ACTIONS CAN DAMAGE THE EQUALIZING BEAM ASSEMBLY AND CAUSE LOSS OF
VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.
LOAD CAPACITY
ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION. ADD-ON AXLE
ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES CAN INCREASE THE SUSPENSION
LOAD ABOVE ITS RATED AND APPROVED CAPACITIES, WHICH CAN RESULT IN COMPONENT
DAMAGE AND LOSS OF VEHICLE CONTROL, POSSIBLY CAUSING PERSONAL INJURY OR
PROPERTY DAMAGE.
MODIFYING COMPONENTS
DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON. DO
NOT SUBSTITUTE REPLACEMENT COMPONENTS NOT AUTHORIZED BY HENDRICKSON. USE
OF MODIFIED, REWORKED, SUBSTITUTE 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, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE
and will Void Warranty. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.
PERSONAL PROTECTIVE EQUIPMENT
ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE
EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTENANCE,
REPAIR OR SERVICE.
PROCEDURES AND TOOLS
A TECHNICIAN 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 WILL ASSUME ALL RISKS OF
CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED.
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.
17730-287
5
JACKING METHODS
IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE AND RESULT IN LOSS OF
VEHICLE CONTROL, SEVERE PERSONAL INJURY OR DEATH AND WILL VOID HENDRICKSON’S
WARRANTY. REFER TO VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.
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 PROCEDURES:
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.
SADDLE CONNECTION
PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL Loctite MATERIAL IS REMOVED FROM THE
Threaded BORES of THE saddle, AND NEW LOCTITE 262 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 SADDLES MUST BE CONNECTED TO THE SPRING MOUNTS AND THE CONNECTING
FASTENERS FULLY TIGHTENED TO THE PROPER TORQUE VALUE BEFORE THE SADDLES ARE
CONNECTED TO THE EQUALIZING BEAM CENTER BUSHINGS. FAILURE TO DO SO COULD RESULT
IN FAILURE OF THE SADDLES OR SPRING MOUNTS, CAUSING LOSS OF VEHICLE CONTROL,
PERSONAL INJURY, OR PROPERTY DAMAGE.
THE SADDLES ARE ATTACHED TO THE CENTER BUSHINGS OF EACH EQUALIZING BEAM WITH TWO
(2) SADDLE CAPS. EACH SADDLE CAP USES TWO (2) BOLTS TO CLAMP THE CENTER BUSHING
INNER METAL TO THE SADDLE. THE SADDLE CAPS MUST BE INSTALLED SO THAT THERE IS AN
EVEN GAP BETWEEN THE SADDLE CAPS AND THE BASE OF THE SADDLE LEGS AS SHOWN IN
FIGURE 3-1. IF THEY ARE NOT INSTALLED EVENLY THE SADDLE LEGS COULD BECOME DEFORMED,
RESULTING IN BENT BOLTS OR DAMAGED SADDLES.
Figure 3-1
Cross tube
IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE which CAN CAUSE LOSS
OF VEHICLE CONTROL, PROPERTY DAMAGE OR SEVERE PERSONAL INJURY AND WILL VOID
HENDRICKSON’S WARRANTY.
■■
DO NOT USE THE SUSPENSION CROSS TUBE AS A JACKING POINT
■■
REFER TO VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.
6
17730-287
SHEAR SPRINGS / SPRING MOUNT - STORED ENERGY
FIGURE 3-2
S TO R E D E N E R G Y CA N CAU S E S E V E R E
PERSONAL INJURY, DEATH, OR PROPERTY
DAMAGE. THE SHEAR SPRINGS AND SPRING
MOUNT ARE INSTALLED IN EACH FRAME
H A N G E R A S S E M B LY U N D E R E X T R E M E
COMPRESSION FORCE. DO NOT ATTEMPT TO
REMOVE THESE COMPONENTS FROM A FRAME
HANGER ASSEMBLY. FRAME HANGER ASSEMBLY
COMPONENTS ARE NOT INDIVIDUALLY
SERVICEABLE, AND MUST BE REPLACED AS A
COMPLETE ASSEMBLY, SEE FIGURE 3-2.
REPLACE ANY SAFETY DECALS THAT ARE FADED,
TORN, MISSING, ILLEGIBLE, OR OTHERWISE
DAMAGED. CONTACT HENDRICKSON CHINA TO
ORDER REPLACEMENT LABELS, SEE FIGURE 3‑3.
FIGURE 3-3 PRODUCT / SAFETY DECAL, NO. 60905-016
FRAME HANGER TIE PLATE
The FRAME HANGER TIE PLATE adds lateral support to the frame hanger assemblies
and helps maintain vertical alignment of the suspension. Loose or improper
installation of the FRAME HANGER TIE PLATE may cause vertical misalignment of the
suspension resulting in premature component wear and replacement. Ensure the
following parameters are met before tightening, or installing the FRAME HANGER
TIE PLATE to the cross member.
■■
All loads are removed from the suspension and the drive axle wheels are off
the ground, or saddles disconnected from spring mount.
■■
The frame hanger assemblies are either snug, or fully tightened to the frame rail.
■■
The FRAME HANGER TIE PLATE is snug, but not fully tightened to the frame
hanger assemblies.
V-Torque RODS
THE 瀚瑞森 HUV 270t SUSPENSION INCORPORATES V-Torque RODS FOR VEHICLE STABILITY.
V-Torque rod is not supplied although it is a required component. IF THESE
COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL THE VEHICLE SHOULD NOT BE
OPERATED. FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE TIRE
CONTACT WITH THE FRAME.
17730-287
7
SECTION 4
Parts Lists
瀚瑞森 HUV 270t
Parts Lists
8
17730-287
KEY NO. PART NO. DESCRIPTION
1
2
1,140 mm Cross Tube
1,370 mm Equalizing Beam Assembly
Includes Key Nos. 3-5
3
Equalizing Beam
4
Center Bushing
5
Bar Pin End Bushing (Non-shim)
Frame Hanger and Saddle Assembly
Includes Key Nos. 6-19
Frame Hanger Assembly
6
Left Front / Right Rear
7
Left Rear / Right Front
8
Progressive Rate Spring
9
68689-000Spacer
10
68690-040
M8 x 1.25 x 40 Flange Bolt
11
68691-000
M8 x 1.25 Flange Nut
12
Frame Hanger Tie Plate
13
67749-075
M20 x 1.5 x 75 mm Flange Bolt
14
67745-000
15
67749-160
16
Saddle
17
Saddle Cap
18
68754-095
19
HUV Product / Patent Label
Not Shown 60937-000
Loctite 262 (Red)
VEHICLE
QUANTITY
1
2
2
2
4
2
2
4
4
16
16
2
12
20
8
4
4
8
1
Varies per
service kit
瀚瑞森 HUV 270t SERVICE KITS
Kit no.
Description
60961-599
Single Saddle Cap Bolt Fastener Service Kit
Page
11
60961-603
Cross Tube Service Kit
11
60961-604
Equalizing Beam Service Kit
11
60961-610
Bar Pin End Bushing Service Kit
11
60961-611
Center Bushing Service Kit
11
60961-606
One Saddle Service Kit
10
Frame Hanger Assembly Service Kit
60961-607 Left Front / Right Rear
10
60961-608 Left Rear / Right Front
10
60961-609
Tie Plate Service Kit
11
60961-605
Progressive Rate Spring Service Kit
10
瀚瑞森 HUV 270t CROSS REFERENCE
Hendrickson DFCV
Part No.
Part No.
Description
60937-000
*Loctite 262 (Red)
60961-599
2904059-K13M0
Single Saddle Cap Bolt Fastener Service Kit
60961-603
2904023-K13M0
Cross Tube Service Kit
60961-604
2971030-K13M0
Equalizing Beam Service Kit
60961-605
2917010-K13M0
60961-606
2971016-K13M0
One Saddle Service Kit
60961-607
2971011-K13M0
Single Frame Hanger Assembly Service Kit (LF/RR)
60961-608
2971021-K13M0
Single Frame Hanger Assembly Service Kit (LR/RF)
60961-609
2904267-K13M0
Tie Plate Service Kit
60961-610
2931125-K13M0
Bar Pin End Bushing Service Kit
60961-611
2931125-K13M1
Center Bushing Service Kit
68689-000 2904263-K13M0Spacer
68690-040
2904012-K13M1
68691-000
2904069-K13M1
67749-075
2904012-K13M2
67745-000
2904069-K13M0
67749-160
2904012-K13M3
68754-095
2904012-K13M0
NOTES End bushing fasteners are not supplied by Hendrickson. Refer to vehicle manufacturer for specifications.
* Included in kit numbers 60961-599, 60961-603, 60961-604, 60961-606, 60961-610, 60961-611.
17730-287
9
Parts Lists
瀚瑞森 HUV 270t Service Kits
Single Frame Hanger Assembly
Left Rear or Right Front
Service Kit No.
60961-608
5
5
2
2
2
1
3
5
5
4
6
KEY NO. PART NO.
DESCRIPTION
1
2
3
4
5
6
LF/RR Frame Hanger Assembly
67745-000
67749-075
67749-160
60961-605
68754-095
Service Kit No.
60961-605
QTY.
1
7
3
4
1
4
Progressive Rate Spring Assembly
One Side
KEY NO. PART NO.
DESCRIPTION
1
2
3
4
5
6
LR/RF Frame Hanger Assembly
Service Kit No.
60961-606
3
3
1
1
2
2
67745-000
67749-075
67749-160
60961-605
68754-095
QTY.
1
7
3
4
1
4
Saddle Assembly
One Saddle
3
3
1
4
4
Shown
HUV 271t
2
4
KEY NO. PART NO.
1
2
3
4
Parts Lists
DESCRIPTION
Progressive Rate Spring
68689-000Spacer
68690-040
68691-000
QTY.
2
2
8
8
KEY NO. PART NO.
1
2
3
4
DESCRIPTION
Saddle
67749-160
67745-000
68754-095
not shown 60937-000
Loctite 262 (Red)
10
QTY.
1
2
2
4
1
17730-287
瀚瑞森 HUV 270t Service Kits
Service Kit No.
60961-599
Saddle Cap Assembly
One Saddle Cap
Service Kit No.
60961-609
Tie Plate Assembly
One Side
1
3
1
2
2
2
KEY NO. PART NO.
DESCRIPTION
1
2
Saddle Cap
Loctite 262 (Red)
68754-095
not shown 60937-000
Service Kit Nos.
60961-603
60961-610
60961-611
QTY.
1
2
1
KEY NO. PART NO.
DESCRIPTION
1
2
3
Frame Hanger Tie Plate
67749-075
67745-000
Service Kit No.
60961-604
Cross Tube Assembly
Bar Pin End Bushing Assembly, One Wheel End
Center Bushing Assembly, One Beam
QTY.
1
6
6
Equalizing Beam Assembly
One Side
1
1
2
3
2
4
KEY NO. PART NO.
DESCRIPTION
60961-603
Cross Tube Service Kit,
Includes Key Nos. 1,4, Loctite
60961-610
Bar Pin End Bushing Service Kit, One
Wheel End, Includes Key Nos. 2,4, Loctite
60961-611
Center Bushing Service Kit, One Beam
Includes Key Nos. 3,4, Loctite
1
1,140 mm Cross Tube
2
Bar Pin End Bushing (Non-shim)
3
Center Bushing
4
68754-095
not shown 60937-000
Loctite 262 (Red)
17730-287
QTY.
KEY NO. PART NO.
DESCRIPTION
1
2
68754-095
60937-000
Equalizing Beam Assembly,
Pre-installed Center Bushing and
Non-shim Bar Pin End Bushing
Loctite 262 (Red)
not shown
QTY.
1
8
2
1
1
1
8
2
11
Parts Lists
SECTION 5
Special Tools
Bar Pin end bushing receiving tool
Bar Pin end Bushing installation tool
Hendrickson Part No. 66086-103
OTC Part No. 1757
Contact info: 800-533-6127 or visit otctools.com
Servicing bar pin end bushings used on 瀚瑞森
HUV 270t equalizing beam suspensions requires the
use of special tooling. Hendrickson part number
66086‑103 adapter set is used with the beam removed
from the truck, and in conjunction with OTC No. 51100
press plate and a 100‑tonne hydraulic shop press.
This shop made tool is designed to receive bar pin end
bushing. Bushing tool is made from cold rolled steel or
equivalent. Drawing is for reference only. Hendrickson
does not supply this tool.
Bar Pin end bushing Removal tools
Center bushing tools
OTC Part No. 206457
OTC Part No. 1746
OTC Part No. 302030
Special Tools
12
17730-287
SECTION 6
Preventive Maintenance
Following appropriate inspection procedures is important to help ensure the proper main‑
tenance and operation of the suspension system and component parts. Hendrickson
recommends the 瀚瑞森 HUV 270t heavy-duty rear suspension be inspected at pre-deliv‑
ery, the first 2,000 kilometers of service and at the regular preventive maintenance intervals.
Off-highway and severe service operating conditions require more frequent inspections
than on-highway service operation. Inspection must include the following items and other
components referenced in this section.
NOTE
Torque values shown in this publication apply only if Hendrickson supplied fasteners are
used. If non-Hendrickson fasteners are used, follow the torque specification listed in the
vehicle manufacturer’s service manual.
Inspection Intervals
Pre-delivery inspection (within first 500 km)
1. Visually inspect suspension for proper assembly
2. Check all fasteners for proper torque with special attention to the following suspen‑
sion connections:
■■
Frame hanger tie plate fasteners,
710-802 Nm
■■
Equalizing beam end connections, per the vehicle manufacturer
■■
Saddle to spring mount fasteners,
■■
Saddle cap bolt fasteners,
■■
Frame hanger to frame rail fasteners, per vehicle manufacturer
710-802 Nm
405-470 Nm
First Inspection (at 2,000 Kilometers or 100 hours)
1. Visually inspect suspension components. Check for all of the following and replace
components as necessary:
■■
Proper suspension function
■■
Signs of unusual movement, loose or missing components
■■
Signs of abrasive or adverse contact with other components
■■
Damaged, or cracked parts
sion connections:
■■
■■
710-802 Nm
Equalizing beam end connections, per the vehicle manufacturer
■■
■■
■■
710-802 Nm
405-470 Nm
PREVENTIVE MAINTENANCE (as part of regular vehicle maintenance intervals)
■■
Every three months / 600 hours inspect progressive rate springs and shear springs.
■■
Every six months / 1,200 hours inspect V-Torque rods, equalizing beam end con‑
nections.
■■
Every twelve months / 2,400 hours:
1. Visually inspect suspension for proper assembly. Visually inspect suspension compo‑
nents. Check for all of the following and replace components as necessary:
17730-287
■■
Proper suspension function
■■
Signs of unusual movement, loose or missing components
13
■■
Signs of abrasive or adverse contact with other components
■■
Damaged, bent or cracked parts
sion connections:
■■
710-802 Nm
■■
Equalizing beam end connections, per vehicle manufacturer
■■
■■
■■
710-802 Nm
405-470 Nm
Component Inspection
Following appropriate inspection procedures are important to help ensure the proper main‑
tenance and operation of the 瀚瑞森 HUV 270t suspension system and component parts
function to their highest efficiency. Look for damaged, bent or cracked parts. Replace all
worn or damaged parts.
■■
Equalizing beam assembly — Check the overall condition of the equalizing beam for
dents, dings, or other damage. Check the beam end connections for tearing or extreme
bulging. Check for any metal-to-metal contact in the bushed joints. Refer to Equalizing
Beam End Connection Inspection in this section.
■■
Fasteners — Look for any loose or damaged fasteners on the entire suspension. Make
sure all fasteners are tightened to a torque value within the specified torque range.
See recommended torque specifications for Hendrickson supplied fasteners in Torque
Specification Section of this publication. For fasteners not supplied by Hendrickson, see
vehicle manufacturer. Use a calibrated torque wrench to check torque in the tightening
direction. As soon as the fastener starts to move, record the torque. Correct the torque
if necessary.
NOTE
Hendrickson recommends the use of Class 10.9 bolts, hardened washers, and Class 10
locknuts. Hardened washers are not necessary when flange head fasteners are used.
NOTE
used. If non Hendrickson fasteners are used, follow the torque specification listed in the
■■
Frame hanger Tie Plate — Inspect frame hanger / cross member to tie plate fasteners
for signs of looseness or movement. Inspect tie plates over all condition for dent, dings
or bent conditions. Components damaged by loose fasteners must be replaced.
■■
Progressive rate spring and shear spring — See progressive rate spring and shear
spring inspection in this section.
■■
V-Torque rods — All V-Torque rods should be inspected every six months. The V‑Torque
rods must be connected and in good working condition when operating the vehicle.
Consult the vehicle manufacturer for inspection, component repair or replacement
instructions.
■■
Wear and damage — Inspect all parts of the suspension for wear and damage. Look
for bent or cracked parts.
See vehicle manufacturer’s applicable publications for other preventive maintenance
requirements.
Equalizing Beam End Connection
The equalizing beam end connection for the 瀚瑞森 HUV 270t is bar pin style with a rubber
bushing, see Figure 6-1.
An inspection of the equalizing beam end connection is necessary when a vehicle is in the
shop for major repair work or every six months, whichever comes first.
14
17730-287
Note
This equalizing beam end connection requires the fasteners be kept tightened to the specified
torque value to maintain the proper clamp load between the axle bracket legs to the bar pins.
All bushing motion is accommodated by rubber deflection.Tighten the beam end fasteners per
the vehicle manufacturer’s specifications.
Figure 6-1
1. Chock the wheels.
2. Visually inspect suspension components for signs of movement or excessive wear.
■■
■■
■■
Inspect equalizing beam end connection for signs of excessive wear or looseness.
A beam end connection, which is visibly cleaner than the other connections, may
indicate a loose connection.
Look for worn, frayed, or distorted rubber in the beam end bushing.
Look for the equalizing beam to be lower in the beam hanger.
Figure 6-2
Figure 6-3
a. Place a jack under each beam end
as shown in Figure 6-3. Raise the
jack to check for movement in the
connection or rubber components.
If movement is noted, DO NOT oper‑
ate the vehicle. Replace the end
bushings and all connecting parts.
The above condition can result in
costly repair, downtime, possible
separation of components, loss of
vehicle control, property damage, or
personal injury.
17730-287
15
Axle Bracket
Supplied by
Vehicle
Manufacturer
Gap in rubber of
Bar Pin End Bushing
If bar pin movement or looseness is noted in the equalizing beam end hub, do not
operate the vehicle. Replace the rubber end bushings and all connecting parts.
The above condition can result in costly repair, downtime, possible separation of
components, loss of vehicle control, property damage, or personal injury.
3. If bar pin movement or looseness is detected in the equalizing beam end hub, DO NOT
operate vehicle. Check and record torque values, as received, for each equalizing beam
end fastener.
4. Correct torque values as required making sure all fasteners are tightened within the
vehicle manufacturer’s specifications.
5. Recheck equalizing beam end connections for signs of looseness.
a. Inspect the equalizing beam end connection for signs of excessive wear or loose‑
ness. A equalizing beam end connection which is visibly cleaner than the other
connections, may indicate a loose connection.
6. If the end bushing bar pin looseness is still detected in the equalizing beam end hub,
DO NOT operate the vehicle. One or more components will require replacement; see
Component Replacement Section of this publication.
Center Bushing
An inspection of the center bushing is necessary when a vehicle is in the shop for major
repair work or every twelve months.
■■
Look for any metal to metal contact.
■■
Look for worn, frayed, or distorted rubber in the center bushing.
■■
Look for the bushing inner metal that is not centered in the bushing.
■■
Look for any equalizing beam to saddle contact.
Figure 6-4
COMPRESSION FORCE. DO NOT ATTEMPT TO
REMOVE THESE COMPONENTS FROM A FRAME
HANGER ASSEMBLY. FRAME HANGER ASSEMBLY
Components ARE NOT Individually
SERVICEABLE, AND MUST BE REPLACED AS A
COMPLETE ASSEMBLY, SEE FIGURE 6-4.
The following points are for guidance and
intended to assist personnel in determining
when frame hanger assembly replacement
is necessary.
NOTE
The Hendrickson 瀚瑞森 HUV 270t suspension frame hanger assembly can be replaced
individually.
Shear spring inspection
■■
A visual inspection of the shear springs is required every three (3) months.
■■
Bent or burred edges on the rate plates extending beyond the rubber are acceptable
provided the rubber can freely expand during vehicle operation.
■■
Creases formed by folding of the rubber surface under load are acceptable. These
appear as stripes on the surface, polished by wear or covered with tacky rubber.
16
17730-287
Figure 6-5
■■
A certain amount of gradual breakup of the
rubber surface is normal. If cuts or splits in
the rubber are over 50 mm length and an
average depth of 13 mm, the frame hanger
assembly requires replacement.
■■
Bonding separation of the rubber from any
of the bonded rate plate surfaces to a max‑
imum depth of approximately 13 mm is
acceptable, see Figure 6‑5. If bonding sep‑
aration depth is 13 mm or more, the frame
hanger assembly requires replacement.
SPRING MOUNT
■■
Inspect the spring mount for damage,
cracks or signs of adverse or abrasive con‑
tact with other components. Replace frame
hanger assembly if spring mount shows cracks or damage.
■■
Inspect spring mount to saddle attaching fasteners for signs of looseness or move‑
ment. Components damaged by loose fasteners must be replaced.
Frame Hanger
■■
Inspect the frame hanger for damage, cracks or signs of adverse or abrasive contact
with other components. Some wear will be evident where the progressive rate spring
contacts the frame hanger assembly. Replace any frame hanger assembly that is
cracked or damaged.
■■
Inspect frame hanger attaching fasteners and frame hanger assembly for signs of
looseness or movement. Components damaged by loose fasteners must be replaced.
Progressive Rate Springs
The following points are for guidance and intended to assist personnel in determining when
progressive rate spring replacement is necessary.
NOTE
The Hendrickson 瀚瑞森 HUV 270t suspension progressive rate springs must be replaced
in pairs (left side pairs or right side pairs), even if only one progressive rate spring shows
unacceptable conditions.
■■
A visual inspection of the progressive rate springs is required every three (3) months.
■■
Height of a new unloaded progressive rate spring is 89.0 mm. The progressive rate
spring requires replacement if the height of the unloaded progressive rate spring
decreases to 64.0 mm or less, see Figure 6-6. If the progressive rate spring is dam‑
aged, replace as outlined in the Component Replacement Section of this publication.
■■
A bent or cracked mounting base requires progressive rate spring replacement.
Figure 6-6
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17
■■
Cuts or splits in the rubber of over 50 mm in length and an average depth of 13 mm
should be considered as possible causes for replacement. A certain amount of gradual
breakup of the rubber surface is normal. The most probable areas for potential cuts,
splits, or wear are shown in Figure 6-6 as “/ / / / / / /.”
■■
Bonding separation of the rubber from the bonded rate plate surface to a maximum
depth of approximately 13 mm is acceptable, see Figure 6-6. If the bonding separation
depth is 13 mm or more, the effected progressive rate spring requires replacement as
outlined in the Component Replacement Section of this publication.
Saddle Cap Bolt Fasteners
PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL LOCTITE MATERIAL IS REMOVED FROM THE
Threaded BORES of THE saddle, AND NEW LOCTITE 262 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 saddles are attached to the center bushings of each equalizing beam with two
(2) saddle caps. Each saddle cap uses two (2) bolts to clamp the center bushing
inner metal to the saddle. The saddle caps must be installed so that there is an
even gap between the saddle caps and the base of the saddle as shown in Figure
6-7. If they are not installed evenly the saddle legs could become deformed,
resulting in bent bolts or damaged saddles.
Figure 6-7
NOTE
Figure 6-8
■■
Apply Loctite 262 (red) to the
threads of the saddle cap
bolts prior to installation.
■■
While tightening the saddle
cap bolt fasteners maintain an
even gap between the saddle
and saddle cap, see Figure
6-7.
■■
Center the saddle on the
equalizing beam center bush‑
ing, see Figure 6-8.
■■
Evenly and in a crosswise
sequence in several steps,
tighten saddle cap bolts to the specified torque to
Figure 6-7.
405‑470 Nm torque as shown in
Tightening the saddle cap bolt fasteners properly will help prevent wear of mating
components, beam center bushing, saddle, and saddle cap.
18
17730-287
Cross Tube
The 瀚瑞森 HUV 270t cross tube connects the two (2) equalizing beams through the
equalizing beam’s center bushings, see Figure 6‑9. The cross tube has clearance to float
side-to-side in the center bushings. The length of the cross tube will allow side-to-side
movement of approximately 50 mm. For this reason, the cross tube may appear polished or
have missing paint at each end where it enters into the center bushings, this is normal. DO
NOT grease the cross tube or the center bushing.
■■
Inspect the overall condition of the cross tube for dents, dings, or bent condition.
Figure 6-9
Axle Brackets
NOTE
The axle brackets are furnished and welded into position by the vehicle manufacturer or axle
manufacturer.
When an equalizing beam is removed for repair or inspected, check for signs of movement.
Also inspect the axle brackets:
■■
For damage and‌/‌or cracks, see Figure 6-10.
■■
Measure the two dimensions on the axle bracket legs, see Figure 6‑10.
An axle bracket outside of the measurement range, damaged or cracked must be repaired
or replaced. Consult the vehicle manufacturer for inspection, component repair and
replacement instructions.
Figure 6-10
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19
V‑Torque Rods
THE 瀚瑞森 HUV 270t SUSPENSION INCORPORATES V-Torque RODS FOR VEHICLE STABILITY.
IF THESE COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL THE VEHICLE SHOULD
NOT BE OPERATED. FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING AND
POSSIBLE TIRE CONTACT WITH THE FRAME or the suspension.
The 瀚瑞森 HUV 270t suspension is equipped by the vehicle manufacturer with V‑Torque
rods that control axle movement during braking, accelerating, and cornering, see Figure 6‑11.
The mounting brackets at the axle ends of the V‑Torque rods are furnished as part of the axle
housings by the vehicle manufacturer or the axle manufacturer. The length of the V‑Torque
rods is determined by the vehicle manufacturer for optimum drive line angles.
Figure 6-11
The frame rail ends are bolted into the brackets supplied by the vehicle manufacturer.
The V‑Torque rods must be connected and in good working condition when operating the
vehicle. Consult the vehicle manufacturer for inspection, component repair or replacement
instructions.
20
17730-287
SECTION 7
Alignment & Adjustments
Alignment
17730-287
■■
The primary control for alignment is the location of the frame hanger assemblies on
the frame rail by the vehicle manufacturer, and the location of the axle brackets on
the axles as installed by the axle or vehicle manufacturer. Additional alignment adjust‑
ments are not possible, refer to the vehicle manufacturer.
■■
Axle centering and pinion angles are controlled by the V-Torque rods. Design, layout,
and installation is the responsibility vehicle manufacturer. Contact the vehicle manu‑
facturer if there are issues relating to axle centering or pinion angles.
■■
Ride height is controlled by the design of the suspension. No adjustment is possible.
However, wear of the progressive rate spring may result in slightly lower ride height over
time. Replacement of worn progressive rate springs should restore suspension ride
height to its original specifications.
21
Alignment & Adjustments
SECTION 8
Component Replacement
Fasteners
When servicing a vehicle Hendrickson recommends replacing all removed fasteners with
new equivalent fasteners. Maintain correct torque values at all times. Check torque values
as specified, see Hendrickson’s Torque Specifications Section of this publication. If non‑Hen‑
drickson fasteners are used follow torque specifications listed in the vehicle manufacturer’s
service manual.
NOTE
used. If non Hendrickson fasteners are used, follow the torque specification listed in the
It is not necessary to replace frame hanger assemblies in pairs. Shear springs and spring
mounts, (see Figure 8‑1) are non-serviceable components of the frame hanger assembly.
Figure 8-1
COMPRESSION FORCE. DO NOT ATTEMPT
TO REMOVE THESE COMPONENTS FROM
A F R A M E H A N G E R A S S E M B LY. F R A M E
HANGER ASSEMBLY Components ARE NOT
Individually SERVICEABLE, AND MUST BE
REPLACED AS A COMPLETE ASSEMBLY, SEE
FIGURE 8-1.
DISASSEMBLY
1. Chock the front wheels of the vehicle to prevent vehicle movement during service.
2. Raise and support the axles on the side of the vehicle being serviced. Remove the
tires from this side of the vehicle.
3. Remove and discard the fasteners that attach the saddles to the two (2) spring
mounts, see Figure 8‑2.
4. Raise the vehicle’s frame just enough to create a 13 mm gap between the saddles
and spring mounts. Support the vehicle’s frame at this height.
5. Remove saddle cap bolts and saddle cap.
6. Remove the saddles.
7. Remove the fasteners connecting the tie plate to the frame hanger assembly being
replaced.
Each frame hanger assembly weighs approximately 40 kilograms, Use appropriate
lifting devices to remove or install the frame hanger assembly. Failure to do so
can result in damage to the vehicle or personal injury.
8. On the frame hanger assembly being replaced remove and discard the frame attach‑
ing fasteners and remove the frame hanger assembly from the vehicle.
22
17730-287
ASSEMBLY
Each frame hanger assembly weighs approximately 40 kilograms, Use appropriate
lifting devices to remove or install the frame hanger assembly. Failure to do so
can result in damage to the vehicle or personal injury.
1. Position the frame hanger assembly against the frame rail and loosely install the
frame attaching fasteners per the vehicle manufacturer’s specifications. Snug but DO
NOT tighten the fasteners at this time.
2. Install the tie plate fasteners to the frame hanger assembly. Tighten the fasteners at
the bolt head to 405‑470 Nm torque plus 90° rotation, alternate tightening torque
710‑802 Nm.
The saddles must be connected to the spring mounts and the connecting
fasteners fully tightened to the proper torque value before the saddles are
connected to the equalizing beam center bushings. Failure to do so could result
in failure of the saddles or spring mounts, causing loss of vehicle control,
personal injury, or property damage.
3. Install the saddle bolts up through the saddle and the spring mounts, see Figure 8‑2.
4. Tighten the saddle to the spring mounts fasteners at the bolt head to 405-470 Nm
plus 90° rotation, alternate tightening torque 710‑802 Nm, see Figure 8-2.
Figure 8‑2
The saddles are attached to the center bushings of each equalizing beam with
two (2) saddle caps. Each saddle cap uses two (2) bolts to clamp the center
bushing inner metal to the saddle. The saddle caps must be installed so that
there is an even gap between the saddle caps and the base of the saddle legs as
shown in Figure 8-3. If they are not installed evenly the saddle legs could become
deformed, resulting in bent bolts or damaged saddles.
5. Remove the frame supports and lower the frame of the vehicle being careful to
engage the saddles on the equalizing beam’s center bushings.
PRIOR TO SADDLE CAP BOLT INSTALLATION, ENSURE THAT ALL RESIDUAL LOCTITE MATERIAL
IS REMOVED FROM THE THREADED BORES OF THE SADDLE, AND NEW LOCTITE 262 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.
6. Apply Loctite 262 to the threads of the saddle cap bolts.
7. While tightening the saddle cap bolt fasteners maintain an even gap between the
saddle and saddle cap, see Figure 8-3.
8. Center the saddle on the equalizing beam center bushing, see Figure 8-4.
17730-287
23
9. Evenly and in a crosswise sequence in several steps, tighten saddle cap bolts to the spec‑
ified torque to 405-470 Nm torque as shown in Figure 8-3.
Figure 8-3
NOTE
Figure 8-4
Ti g h te n i n g t h e s a d d l e c a p
bolt fastener s properly will
help prevent wear of mating
c o m p o n e n t s, b e a m c e n t e r
bushing, saddle, and saddle cap.
10. Tighten the frame hanger to
frame attaching fasteners
per the vehicle manufactur‑
er’s specifications.
11. Install the tires.
12. Remove the support from
the axles and lower the vehi‑
cle onto the ground.
13. Remove the wheel chocks.
Progressive Rate Spring and Spacer
NOTE
The Hendrickson 瀚瑞森 HUV 270t suspension progressive rate springs must be replaced
in pairs (left side pairs or right side pairs), even if only one progressive rate spring shows
unacceptable conditions.
Figure 8-5
DISASSEMBLY
1. Chock the front wheels of the
vehicle to prevent vehicle move‑
ment during service.
2. Raise the vehicle’s frame until
the spring mounts contact the
bottom of the frame hanger
assembly. Support the vehicle’s
frame at this height.
3. Remove and discard the four
fasteners that attach the pro‑
gressive rate spring and spacer
to the spring mount.
4. Remove the progressive rate
spring spacer and the progressive rate spring from the
24
17730-287
ASSEMBLY
1. Install the progressive rate spring into the frame hanger assembly and hold it up
against the ceiling of the frame hanger opening.
2. Install the spacer between the spring mount and the progressive rate spring.
The progressive rate spring fasteners must be installed with the locknuts under the
spring mount. If the fasteners are installed upside down, in the incorrect orientation,
the fasteners will contact the frame hanger causing component damage.
3. Install the four fasteners that attach the progressive rate spring to the spring mount.
The fasteners MUST be installed with the locknuts under the spring mount as shown
in Figure 8-5.
4. Tighten the progressive rate spring fasteners to
23-26 Nm torque.
5. Remove the frame supports and lower the vehicle.
Saddle
DISASSEMBLY
1. Chock the front wheels of the vehicle to prevent vehicle movement during service.
2. Raise and support the axles on the side of the vehicle being serviced. Remove the
tires from this side of the vehicle.
3. Remove and discard the fasteners that attach the saddles to the two (2) spring
mounts, see Figure 8‑6.
and spring mounts. Support the vehicle’s frame at this height.
5. Remove saddle cap bolts and saddle cap, see Figure 8‑6.
6. Remove the saddles.
Figure 8-6
17730-287
25
ASSEMBLY
The saddles must be connected to the spring mounts and the connecting
fasteners fully tightened to the proper torque value before the saddles are
connected to the equalizing beam center bushings. Failure to do so could result
in failure of the saddles or spring mounts, causing loss of vehicle control,
personal injury, or property damage.
1. Position the saddle against the spring mounts and install the saddle bolts up through
the saddle and spring mounts, see Figure 8‑6.
2. Tighten the saddle to the spring mounts fasteners at the bolt head to 405-470 Nm
plus 90° rotation, alternate tightening torque 710‑802 Nm, see Figure 8‑6.
INNER METAL TO THE SADDLE. THE SADDLE CAPS MUST BE INSTALLED SO THERE IS AN EVEN
GAP BETWEEN THE SADDLE CAPS AND THE BASE OF THE SADDLE AS SHOWN IN FIGURE 8-7. IF
THEY ARE NOT INSTALLED EVENLY THE SADDLE LEGS COULD BECOME DEFORMED, RESULTING
IN BENT BOLTS OR DAMAGED SADDLES.
Figure 8-7
Figure 8-8
4. Apply Loctite 262 to the
bolts.
5. While tightening the saddle
cap bolt fasteners maintain
an even gap between the
saddle and saddle cap, see
Figure 8-7.
6. Center the saddle on the
equalizing beam center
7. Evenly and in a crosswise
Figure 8-7.
NOTE
405-470 Nm torque as shown in
components, beam center bushing, saddle and saddle cap.
26
17730-287
9. Remove the support from the axles and lower the vehicle on to the ground.
Equalizing Beam
SERVICE HINT
It is recommended to remove both equalizing beams and the cross tube as a group even if
only one equalizing beam needs service.
DISASSEMBLY
1. Chock the wheels of the steer axle and all drive axles to prevent vehicle and/or axle
movement during service.
2. Support the pinion of the drive axles to prevent axle movement during service.
3. Remove the saddle cap bolts from both inboard and outboard sides of both equaliz‑
ing beam’s center bushings. Remove the saddle caps, see Figure 8‑9.
and the center bushings. Support the vehicle’s frame at this height.
5. Support both equalizing beams under the center bushing with floor jacks.
6. Remove and discard all equalizing beam end attaching fasteners.
7. Slowly lower the floor jacks and remove the equalizing beams from the axle brackets.
8. Remove the floor jacks from under the equalizing beams.
Figure 8-9
ASSEMBLY
1. Position the equalizing beams under the axles with a floor jack under the center of
each equalizing beam.
SERVICE HINT
Ensure the equalizing beam’s center bushing end plug is located on the outboard side, see
Figure 8‑9.
2. Install the cross tube into the center bushing of each beam.
SERVICE HINT
17730-287
Increasing or decreasing the pinion angle may help align the axle bracket and equalizing
beam end bushings.
27
3. Using the floor jacks, slowly raise both equalizing beams and cross tube as an assem‑
bly into the axle brackets. Ensure that each equalizing beam end bushing correctly
engages the axle bracket.
4. Install new equalizing beam end fasteners through the axle brackets and equalizing
beam end bushings. Tighten the equalizing beam end fasteners per the vehicle manu‑
facturer’s specifications.
INNER METAL TO THE SADDLE. THE SADDLE CAPS MUST BE INSTALLED SO THERE IS AN EVEN
GAP BETWEEN THE SADDLE CAPS AND THE BASE OF THE SADDLE AS SHOWN IN FIGURE 8-10. IF
THEY ARE NOT INSTALLED EVENLY THE SADDLE LEGS COULD BECOME DEFORMED, RESULTING
IN BENT BOLTS OR DAMAGED SADDLES.
Figure 8-10
Figure 8-11
6. Apply Loctite 262 to the
bolts.
7. While tightening the saddle
cap bolt fasteners maintain
an even gap between the
saddle and saddle cap, see
Figure 8-10.
8. Center the saddle on the
equalizing beam center
9. Evenly and in a crosswise
Figure 8-10.
NOTE
405-470 Nm torque as shown in
components, beam center bushing, saddle, and saddle cap.
11. Remove the supports from the drive axles and lower the vehicle onto the ground.
28
17730-287
Center Bushing
Before attempting to remove the equalizing beam center bushings, inspect the inside face of
each equalizing beam center hub. If the outer metal of the center bushing is worn, the edge
may have mushroomed over the face of the beam hub. This material must be removed with
a chisel or disc sander before the tooling adapters can be positioned for bushing removal.
You will need
■■
Vertical shop press with a capacity of at least 45 metric tonnes.
■■
Center Bushing Service Kit, see Parts List Section of this publication.
■■
Center Bushing Tool – Refer to the Special Tools Section of this publication for the kit
necessary to remove and install 瀚瑞森 HUV 270t rubber center bushings.
■■
Bar Pin End Bushing Receiving Tool – The receiving tool is a shop made tool which
completely supports the beam hub being serviced and is tall enough to receive the
bushing as it is being pressed in or out.
DISASSEMBLY
1. Remove the equalizing beam assembly from the vehicle. Follow the equalizing beam
disassembly procedure in this section.
Do not use a cutting torch to remove any fasteners or bushings. 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.
2. Place the equalizing beam assembly in a shop press with the center hub firmly sup‑
ported on the receiving tool.
3. Install the center bushing removal tool centered on the center bushing.
4. Push directly on center bushing removal tool until the center bushing is pressed out of
the equalizing beam bore.
5. Inspect beam bores.
INSPECTION
After removing the center bushings, thoroughly inspect the beam bores. If damaged from
center bushing removal, replace with a new equalizing beam. DO NOT perform a center
bushing replacement or other service procedure on an equalizing beam that has been
damaged.
Failure to replace an equalizing beam that has been damaged from center bushing
removal can result in the failure of that equalizing beam, leading to loss of
vehicle control and possible personal injury or property damage.
When installing rubber center bushings the following steps will minimize the chance of
damaging a new bushing:
1. Clean the bores of the equalizing beams with emery cloth, removing any nicks or
metal buildup from bushing removal.
2. Measure the inside diameter of the equalizing beam’s center bore and the center
bushing’s outside diameter. Take any two readings at 90 degrees in the same plane,
see Figure 8‑12, maximum ovality 0.254 mm. If either component is not within the
specified range, replacement is required.
17730-287
29
Figure 8-12
The specification for the inside
diameter of the equalizing beam’s
center bore is 120.50 mm /
120.29 mm
3. The equalizing beam bore
may have a more substantial
lead-in chamfer at one end
of the bore than the other.
Take advantage of the larger
chamfer by pressing in the new center bushing from this end.
4. Support the beam squarely at the bore area to avoid distortion of the beam bore or
bending of the beam.
5. Lubricate the outer diameter (O.D.) of the center bushing and the inner diameter (I.D.)
of the beam bore with an NLGI#2 – EP (Extreme Pressure) lithium base grease.
6. Make sure the bushing is square to the equalizing beam bore and press the bushing
into beam.
ASSEMBLY
Figure 8-13
1. Place the equalizing beam in
a shop press on the receiving
tool or press. Support the beam
squarely at the bore area to avoid
distortion of the beam bore or
2. Lubricate the equalizing beam
bore and the equalizing beam
center bushing outer metal
sleeve with an NLGI #2 – EP
(Extreme Pressure) grease.
NOTE
The center bushing must be square
with the equalizing beam end hub
before pressing the center bushing
into the beam. Center bushings pressed in at an angle will damage the end bushing and
the equalizing beam.
3. Install the center bushing installation tool and press in the new center bushing until
the outer metal sleeve is centered in the equalizing beam bore, see Figure 8-13.
4. Install the equalizing beam assembly to the vehicle. Follow the equalizing beam
installation procedure in this section.
Bar Pin End Bushings
You will need:
■■
A shop press with a capacity of at least 45 metric tonnes
■■
End Bushing Kit, see Parts List Section of this publication.
■■
Bar Pin End Bushing Tools – Refer to Special Tools Section of this publication for the
tools to remove and install the 瀚瑞森 HUV 270t bar pin style rubber end bushings.
■■
Bar Pin End Bushing Receiving Tool – The receiving tool is a shop made tool (see
Special Tools Section of this publication) which completely supports the beam hub
being serviced and is tall enough to receive the bushing as it is being pressed in or out.
30
17730-287
When removing and installing bushings in the equalizing beams, follow the
procedures outlined in this publication. Do not use a cutting torch to remove the
bushing outer metals pressed in the beam bores or fasteners. Welding, torching
or attaching material to the equalizing beam must never be performed. The use of
heat CAN adversely affect the strength of the equalizing beams.
DISCARD USED FASTENERS. ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR. FAILURE TO
DO SO COULD RESULT IN FAILURE OF THE PART OR MATING PARTS, LOSS OF VEHICLE CONTROL,
PERSONAL INJURY, OR PROPERTY DAMAGE.
NOTE
Hendrickson recommends the use of Class 10.9 bolts, hardened washers, and Class 10
locknuts. Hardened washers are not necessary when flange head fasteners are used.
Figure 8-14
Bushing Removal
1. Remove equalizing beam assembly from vehicle as
detailed in the equalizing beam disassembly instruc‑
tions in this section.
2. Place the equalizing beam in the shop press with the
beam end hub squarely supported on the receiving tool.
3. Press on the end bushing inner metal, see Figure 8‑14,
of the end bushing until the inner metal is flush with the
top of the beam end hub. This will dislodge the confine‑
ment washer and move the bushing rubber away from the outer metal of the bushing
so the removal tool can be installed.
4. Center the bushing removal tool directly on the bushing’s outer metal and press the
bushing out of the beam end hub.
5. After removing the equalizing beam bushings, thoroughly inspect each beam bore.
INSPECTION
After removing the bar pin end bushings, thoroughly inspect the beam bores. If the
equalizing beam is damaged from end bushing removal, replacement of the equalizing
beam is required, replace with a new equalizing beam. DO NOT perform a end bushing
replacement or other service procedure on an equalizing beam that has been damaged.
Failure to replace an equalizing beam that has been damaged from end bushing
removal can result in the failure of that equalizing beam, leading to loss of
vehicle control and possible personal injury or property damage.
When installing bar pin end bushings the following steps will minimize the chance of ruin‑
ing a new bushing:
1. Clean the bores of the equalizing beams with emery cloth or hone, removing any
nicks or metal buildup from bushing removal.
2. Measure the equalizing beam end hub bore inner diameter and the bushing outside diam‑
eter. If components are not within the specified range, replacement is required.
Figure 8-15
The Hendrickson specification for the equal‑
izing beam end hub bore diameter is 110.97
mm / 110.77 mm, see Figure 8-15.
3. The equalizing beam bore may have
a more substantial lead chamfer at
one end of the bore than the other.
Take advantage of the larger chamfer
by pressing in the new center bushing
from this end.
4. Support the beam squarely at the bore area to avoid distortion of the beam bore or
17730-287
31
5. Lubricate the outer metal of the bar pin end bushing and the inner diameter of the
beam end hub with an NLGI #2 – EP (Extreme Pressure) lithium base grease.
6. Make sure the bushing is square to the beam bore and press the bushing into beam.
NOTE
Always use the bushing’s outer metal for pressing operations, unless otherwise instructed.
Pressing on the bushings inner metal may damage the bushing requiring bushing
replacement.
End Bushing Installation
1. Place the equalizing beam in a shop press with the end hub, see Figure 8-16 and
8-28, squarely supported on the receiving tool.
2. Install the end bushing installation tool (refer to Special Tools Section of this publica‑
tion) on the new end bushing as shown in Figure 8‑17. Tighten the through bolt until
the two halves of the tool touch. The installation tool compresses the rubber between
the inner and outer metal of the bushing to allow press force to be transmitted only to
the outer metal of the bushing.
Figure 8-16
Bar Pin End Bushing
Outer Metal
Lubricate the inside diameter of
END HUB and the bar pin end
bushing OUTER METAL with
NLGI#2-EP (Extreme Pressure)
lithium base grease
Equalizing Beam
End Hub
Equalizing Beam
3. Lubricate the equalizing beam end hub inside diameter AND the bar pin end bush‑
ing’s outer metal with a heavy layer of NLGI #2 – EP (Extreme Pressure) lithium base
grease, see Figure 8-16.
4. Position the equalizing beam end bushing and installation tool on the end hub. Verify
the bolt holes in the end bushing are in line with the beam axis, see Figure 8-17.
NOTE
The end bushing must be square with the equalizing beam end hub before pressing the end
bushing into the beam. End bushings pressed in at an angle will damage the end bushing
and the equalizing beam.
Figure 8-17
5. Verify the end bushing’s outer metal is square with the end hub. Equalizing beam and
end bushing damage will result if the bushings are pressed in at an angle.
CARE MUST BE TAKEN DURING THE INSTALLATION OF THE BUSHING. DO NOT PUSH ON THE INNER
METAL OF THE BUSHING, DOING SO WILL CAUSE DAMAGE TO THE BUSHING AND VOID WARRANTY.
6. Install the end bushing into the end hub by pressing on the installation tool until the
installation tool contacts the end hub. This will center the bushing in the end hub, see
Figure 8-18.
32
17730-287
7. Install the equalizing beam
assembly into vehicle as detailed
in equalizing beam assembly in
this section.
Figure 8-18
Bar Pin
Equalizing Beam
End Hub
Outer metal is
centered in the
equalizing beam
end hub
Cross Tube
The 瀚瑞森 HUV 270t cross tube connects the two (2) equalizing beams through the
equalizing beam’s center bushings. Figure 8‑19. The cross tube has clearance to float sideto-side in the center bushings. The length of the cross tube will allow side-to-side movement
of approximately 60 mm. For this reason, the cross tube may appear polished or missing
paint at each end where it enters into the center bushings. This is normal. DO NOT grease
the cross tube or center bushing.
A cross tube seldom requires replacement, usually only when it has been bent, possibly
due to hitting an unseen object. A bent cross tube will cause misalignment of the axles, and
must be replaced immediately to eliminate abnormal tire wear. Replacement of the cross
tube requires removal of both equalizing beams. Follow the equalizing beam disassembly
procedure in this section.
Figure 8-19
17730-287
33
SECTION 9
Torque Specifications
HUV 270t
Hendrickson recommended torque values
provided in Nm and in Foot Pounds
2.
Preferred Tightening Method
405-470 Nm (299-347 ft. lbs.)
plus 90° Rotation
Alternate tightening
710-802 Nm (524-592 ft. lbs.)
Tighten at the bolt head
3.
23-26 Nm (17-19 ft. lbs.)
3.
23-26 Nm
(17-19 ft. lbs.)
1.
Preferred Tightening Method
405-470 Nm (299-347 ft. lbs.)
plus 90° Rotation
Alternate tightening
710-802 Nm (524-592 ft. lbs.)
Tighten at the bolt head
4.
405-470 Nm (299-347 ft. lbs.)
Apply Loctite 262 to the threads
of the Saddle Cap bolts
34
17730-287
瀚瑞森 huv 270t
HENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS
NO.
COMPONENT
*QUANTITY
SIZE
**TORQUE VALUE
Preferred Tightening
Nm
Foot Pounds
8
M20 x 1.5 x 160 mm
Flange Bolt
405-470 Nm
(299-347 ft. lbs.)
plus
90° rotation
710-802
524-592
405-470 Nm
(299-347 ft. lbs.)
plus
90° rotation
710-802
524-592
1
Spring Mount to Saddle
at the Bolt Head
2
Frame Hanger to Tie Plate
at the Bolt Head
12
M20 x 1.5
Flange Nut
3
Progressive Rate Spring to
Spring Mount
16
M8 x 1.25
Flange Nut
Not applicable
23-26
17-19
4
***Saddle Cap to Saddle
8
M20 x 2.5 x 95 mm
Flange Bolt
Not applicable
***405-470
***299-347
NOTE: * Quantities shown are per suspension.
**Torque values shown in this publication apply only if Hendrickson supplied fasteners are used. If non Hendrickson
fasteners are used, follow the torque specification listed in the vehicle manufacturer’s service manual.
*** Apply Loctite 262 to the threads of the saddle cap bolts before installation.
17730-287
35
SECTION 10
Troubleshooting Guide
瀚瑞森 HUV™ 270t TROUBLESHOOTING GUIDE
CONDITION
Suspension has harsh or
bumpy ride
Vehicle leans
Irregular tire wear
POSSIBLE CAUSE
CORRECTION
Damaged progressive rate spring
Replace progressive rate springs, must be replaced in pairs
Damaged shear spring
Replace frame hanger assembly
Vehicle overloaded
Redistribute or reduce load to correct weight
Damaged progressive rate spring
Replace progressive rate springs, must be replaced in pairs
Damaged shear spring
Weight bias
Redistribute load to correct weight bias
Incorrect axle alignment
Axle alignment is permanently set at the time of vehicle
manufacture. Contact vehicle manufacturer.
Bent cross tube
Replace cross tube
Damaged, bent, cracked suspension
component
Replace damaged component
Reduce and/or redistribute load to correct weight
Suspension is overloaded
Loose or missing
suspension fasteners
Replace and/or properly tighten fasteners to the proper
torque specification
Increase inspection interval of fasteners
Frequent hard stop/start
Review driving habits to reduce frequency of hard stop/start
Replace and/or properly tighten fasteners to the proper
torque specification
Suspension is overloaded
Reduce and/or redistribute load to correct weight
Frame hanger cracked
Saddle leg to equalizing
beam contact
Loose or missing suspension
fasteners
Increase inspection interval of fasteners
Damaged frame hanger assembly
Damaged, bent, worn, or cracked
suspension component(s)
Replace damaged component
Cross tube bent or missing
Replace cross tube
Loose or worn saddle cap
Replace saddle cap and/or saddle
Saddles not center on equalizing beam
Center saddles on the equalizing beam
Replace fasteners and/or properly tighten fasteners to the
proper torque specification
www.hendrickson-intl.com.cn
Hendrickson China
Shanghai Add: Suite 2402B, Baoan Building,
800 Dongfang Road, Pudong New Dist, Shanghai, 200127
Factory Add: No. 1668 North Section of Chunbo Road.
East New Dist of Jinan High Tech Industrial Development Zone,
Jinan, Shandong, P.R.C, 250104
17730-287 Rev A 06-15
Phone +86 21 5876 5710
Fax +86 21 5876 1577
Phone: +86 531 8880 9055
Fax : +86 531 8880 9059
Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected.
© 2015 Hendrickson USA, L.L.C. All Rights Reserved
Printed in China

17730-287 Rev A, Technical Procedure HUV 270t for Dongfeng

Transcription

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