peterbilt rear air suspensions adjustment

42
FIELD SERVICE BULLETIN A DIVISION OF ilqN Date: File Group: ATTENTION: ServiceManager Distribution Copy: /Dealer Principal lWarranly Manager /Parls Manager /Sales Manager Setting/Adiusting RearAxle Angles: Proprietary RearAir Susoensions ExceptFLEXA|TTM This bulletin is applicable to vehicles equipped with proprietary rear air suspensions exceot FLEXAirrM suspensions; i.e., Air Leaf,Low Air Leaf, Low Low Air Leaf, and Air Tracsuspensions. lt provides a procedure to set ride height and adjust rear axle angles on those vehicles. . Thisbulletin supersedes the information on "Measuring Pinion Angle" and "Setting Air Spring Height (RideHeight)" in Section 6, "Rear Suspension" of the master mainte- nance manual for vehiclesequipped as described above. The manual will be updated in the nearfuture to reflect the changes madeby this bulletin. The ride height of proprietary rear air suspensions is set at the factory. The specifications usedare designed to provide the vehicle withthe bestpossible axletravel and ridecharac- teristics. There are occasions whena customer will reset or adjust the rideheight after a vehicle has beenput in service. Peterbilt recommends against thisfor the following reasons: ' Changing the ride height results in a change in rearaxledriveline angles. This situa- tioncan leadto driveline vibration. ' Changing the ride height may havea detrimental effect on axle travel, and may also result in complaints of rough ride. Peterbilt recommends that customers be encouraged to avoidthesepotential problems by maintaining the ride heightat the factorysetting. When necessarythe rear axle angle(s) should be returned to the original factory specification. A new adjustment pro- cedure that removes the effect of frame rake variation on pinion angles was implemented on 6/26199 (Denton) and 814199 (Madison). Using this method permits setting reardriver and interaxle driveshaft angles to provide the best possible axle travel and U-joint can- cellation as well as keeptorsional acceleration within specifications. The procedure and supporting information is contained in this bulletin. The special ride height tool required for this procedure is available from PACCAR Parts(see PartsNotesbelow). PartsNotes The parts referred to in this bulletin are listed belowand available from PACCAR Parts using normal ordering procedure. April7,2004 03 Section: Rear Suspension Part Number Description +z-uuz]v-uu1 Kroe nergnr roor (gauge) J3-U6 /6U-0U1 , -002,-003, -004 Axle shim(forLowAir Leaf suspensions on/after 415104) Pro3600 Anglemaster Inclinometer (available at http://www. penntoolco. com/cataloq/products/697. cfm) PS803035 F.S.B.# 3-00R Page 1 of 42

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Page 1: Peterbilt Rear Air Suspensions Adjustment

FIELD SERVICEBULLETIN A DIVISION OF ilqN

Date:

File Group:

ATTENTION: ServiceManager

Distribution Copy:/Dealer PrincipallWarranly Manager/Parls Manager/Sales Manager

Setting/Adiusting RearAxle Angles: Proprietary RearAir Susoensions Except FLEXA|TTMThis bulletin is applicable to vehicles equipped with proprietary rear air suspensionsexceot FLEX AirrM suspensions; i.e., Air Leaf, Low Air Leaf, Low Low Air Leaf, and AirTrac suspensions. lt provides a procedure to set ride height and adjust rear axle angleson those vehicles.

. This bulletin supersedes the information on "Measuring Pinion Angle" and "Setting AirSpring Height (Ride Height)" in Section 6, "Rear Suspension" of the master mainte-nance manual for vehicles equipped as described above. The manual will beupdated in the near future to reflect the changes made by this bulletin.

The ride height of proprietary rear air suspensions is set at the factory. The specificationsused are designed to provide the vehicle with the best possible axle travel and ride charac-teristics.

There are occasions when a customer will reset or adjust the ride height after a vehicle hasbeen put in service. Peterbilt recommends against this for the following reasons:

' Changing the ride height results in a change in rear axle driveline angles. This situa-tion can lead to driveline vibration.

' Changing the ride height may have a detrimental effect on axle travel, and may alsoresult in complaints of rough ride.

Peterbilt recommends that customers be encouraged to avoid these potential problemsby maintaining the ride height at the factory setting. When necessary the rear axleangle(s) should be returned to the original factory specification. A new adjustment pro-cedure that removes the effect of frame rake variation on pinion angles was implementedon 6/26199 (Denton) and 814199 (Madison). Using this method permits setting rear driverand interaxle driveshaft angles to provide the best possible axle travel and U-joint can-cellation as well as keep torsional acceleration within specifications. The procedure andsupporting information is contained in this bulletin. The special ride height tool requiredfor this procedure is available from PACCAR Parts (see Parts Notes below).Parts NotesThe parts referred to in this bulletin are listed below and available from PACCAR Partsusing normal ordering procedure.

April7,2004

03 Section: Rear Suspension

Part Number Description+z-uuz]v-uu1 Kroe nergnr roor (gauge)J3-U6 /6U-0U1 , -002, -003, -004 Axle shim (for Low Air Leaf suspensions on/after 415104)Pro 3600 Anglemaster Inclinometer (available at

http://www. penntoolco. com/cataloq/products/697. cfm)

PS803035 F.S.B. # 3-00R Page 1 of 42

Page 2: Peterbilt Rear Air Suspensions Adjustment

Setting and Adjusting Ride Height and Rear Axle Angles

WARNING! This procedure requires seruicing the vehicle with the trans-mission in neutral and the parking brakes released. The vehicle must beparked on a completely flaUlevel surface with both front wheels chockedon both sides. Failure to adequately chock the wheels may lead to thevehicle rolling into someone/something, causing an accident and possi-ble serious personal injury and/or equipment damage.

NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4

Follow this procedure to set ride height and adjust rear axle angles (pinion angles).1. Ensure that the following tools are available:. Ride height tool (gauge). Pro-3600 or Pro-360 Anglemaster (inclinometer). Adapter for Anglemaster

2. Drive the vehicle onto a flaUlevel surface. Back straight out for the length of the vehi-cle and slowly drive back onto the flaUlevel surface. Gently roll to a stop. Place thetransmission in neutral and set the parking brakes.

3. Chock the front wheels on both sides.4. Release the parking brakes.5. Ensure that the ride height gauge has the correct slide installed for the suspension on

the vehicle (see "NOTES" in Figure 1).

-3t MOVE GAGE UNDER RAIL BETWEEN TANDEMS,/ ANO RAISE SLIDE TO CONTACT BOTTOi' FI-ANGE

"tr-t@

LOW AIR LEAF (Srngleaxle conirgurations burllon & atter 4/904) and

SOUEEZ E TABS TOSLIDE POINTER

LOWLOWAIR -----> 2) AL|GN POTNTER W|TH AXLE HUB HOLE

Lol^/ AIR LEAF(includes Srngleconliguralons builtbelore 4/5/04)

TIGHTEN WING NUTTO HOLD POINTER

POSITION

lDOES PROPER INDICATOR GROOVE

APPEAR IN TOLEMNCE AOX?YES. G@DNO - ADJUST BIDE HEIGHT

APPLY PN, REV LEVELAND SUPPLIER CODE

LooK HERE TO DETERMINE PROPERINDICATOR GROOVE PER SI.JSPENSION

o1) PLACE BASE ON LEVEL GROUNO

NEAR REAR REAR AXLE

Figure 1 lllustration of Ride Height Gauge

MATERIAL LIST

1 ,42d218-001. BASE

2 42{n'217 -0o1,SLIDE (ALTERMTE SLTDE 42-00220-001, SEE NOTES 1 AND 2)

3 142{0216{01, POINTER

n lseecen lwr .zso' ALuMTNUM TUBTNG, 4-1l,16' LoNG)

NOTES:

1) WITH AIR LEAF, AIR TRAC, LOW AIR LEAFAND LOW LOW AIR LEAF USE STANDARDsLIDE 42-0021 7-001

2) WITH REYCO 1O2AR AND NEWAY AIR SUSPENSIONS-USE ALTERNATE SLIDE 42.OO22O.OO1 (NOT INCLUDED

wrTH ASSEMBLY 42-00219-001 )

3) SPACER (ITEM 4) SITS LOOSE IN BOTTOM OFOUTER TUBE OF ITEM 1

4) DASH VARIATION INDICATES TOOL NUMBER

U \

Page2 of 42 F.S.B. # 3-00R PS803035

Page 3: Peterbilt Rear Air Suspensions Adjustment

6 .

7 .

Place the ride height gauge near the rearmost axle such that the base is on levelground (see Figure 1 and Figure 2 ).Align the pointer of the gauge with the axle hub hole (see Figure 2).

a. Squeeze the tabs to slide the pointer into proper position.

b. Tighten the wing nut to hold the pointer in that position.

ALIGN POINTER WITH AXLE HUB HOLE

, - - - >

Figure 2 l l lustration of Aligning The Pointer of a Ride Height Gauge

PS803035 F.S.B. # 3-00R Page 3 of 42

Page 4: Peterbilt Rear Air Suspensions Adjustment

8. Move the ride height gauge under the frame rail, either forward of a single axle (butnot forward of the suspension bracket) or between tandem axles (see Figure 3).

Figure 3 lllustration of Measuring The Ride Height on a Tandem Suspension

9. Raise the slide to bring the magnet at its tip into contact with the bottom flange of theframe rail.

Page 4 ot 42 F.S.B. # 3-00R PS803035

Page 5: Peterbilt Rear Air Suspensions Adjustment

, \, / . ) / MOVEGAGEUNDERRAILBETWEENTANDEMS

MAGNET ,/ AND RAISE SLIDE TO COMTACT BOTTOM FLANGE

10. Look in the tolerance box and note what indicator groove appears (see Figure 4).. lf the proper groove appears, skip to Step 16 in this procedure.. lf the proper groove doesn't appear, perform all remaining steps in this procedure.

LOW AIF LEAF (Srng le

axle conliguraions buillon & after 4/5/G) and

LOWLOWAIR

LOW AIR LEAF(n rc ludes S ing le a )

configuralons burllbelore 4/Y04)

DOES PROPER INOICATOR GROOVEAPPEAR IN TOLEMNCE BOX?YES. G@DNO. ADJUST RIDE HEIGHT";1\

.|f

o r r / i lLOOK HERE TO OETERMINE PROPERINOICATOR GROOVE PER SUSPENSIoi']

Figure 4 lllustration of Checking Ride Height lndicator

11.Loosen the fasteners mounting the height control valve to its bracket. See Figure5for illustrations of height control valves.

NOTE: At least one of the mounting holes in the height control valve bracket willbe slotted to permit rotating the valve.

12.Rotate the valve either clockwise or counterclockwise to obtain the appropriate rideheight as measured with the ride height gauge.

13.When at the appropriate ride height, ensure that the height control valve lever is inthe neutral position, then install either the built-in alignment pin or a 1/8-inch (3 mm)dowel.

14.Torque the mounting fasteners to 55 - 75 Lb. in. (6.2 - 8.5 N.m.).

15. Remove the alignment pin or dowel.

PS803035 F.S.B. # 3-00R Page 5 of 42

Page 6: Peterbilt Rear Air Suspensions Adjustment

NEWAY HEIGHT CONTROL VALVE

INTAKE

CONTROLT

ADJUSTINGLOCK NUT

3t16"ROO

ADJUSTINGLOCK .

ARM

EXHAUST\

EXHAUST.,OUT" TA I R S P R I N G

, , IN ' ' A IR SUPPLY

BOTTOM

HADLEY HEIGXT CONTROL VALVE

AIUUSTINGLOCK NUTINTAKE

EXHAUST \

€XHAUST..IN" AIR SUPPLY

Figure 5 lllustrations of Height ControlValves

Page 6 of 42 F.S.B. # 3-00R

7tE',ALIGNMENT

ROD

80770M

PS803035

Page 7: Peterbilt Rear Air Suspensions Adjustment

[Tl NOTE: Contact PACCAR Pafts Research (1-800-477-0251) to obtain rear

LU axle angle information for newer vehicles whose records are not yet in ECAT.

16.Obtain the specified forward rear axle angle from the vehicle's FCBM. This informa-tion is located in the vehicle's record in ECAT.

. See F.S.B. #4-92R for instructions to read rear axle angle information.

. Refer to Figure 6 and Figure 7 for examples of rear axle angle bills.

Figure 6 Example of Rear Axle Angle Information Bill (Parallel Axle Configuration)

PS803035 F.S.B. # 3-00R PageT of 42

Page 8: Peterbilt Rear Air Suspensions Adjustment

Figure 7 Example Rear Axle Angle Information Bill (Broken-back Axle Configuration)

17.Zero the inclinometer to the LH frame rail with the face of the inclinometer orientedinboard (i.e., toward the passenger side of the chassis) as shown in Figure 8 .

Figure 8 lllustration of Inclinometer on the Left-Hand Frame Rail

Page 8 of 42 F.S.B. # 3-00R PS803035

Page 9: Peterbilt Rear Air Suspensions Adjustment

iB.Measure and record the forwarci rear axle angiehousrng, near the axle seat, on the long side ofented inboard as shown in Fioure 9 .

/\

at e i ther theihe ax le, wi th

top or bottom of thethe incl inometer or i -

.#

Figure I l l lus t rat ion of Using an Inc l inometer to Determine Forward Rear Axle Angle

l9.Compare the forward rear ax le angle you obta ined to the va lue l is ted in the FCBM:' l f the angle is wi th in t 0 .5 degree of that va lue, e i ther s top ( for s ing le ax le conf igura-

t ions) or proceed to Step 20 ( for tandem axle conf igurat ions) .

NOTE:' Shinirning may not be requireci if the proper axle angle can be obtained by

adjusting the ride height within the tolerance window.' Ensure that the specified ride height is maintained during axle angle adjust-

. ment so that a valid inclination measurement is achieved.

|e4s_l'/qteo" l f the angle di f ters by more than t 0.5 degree from the value, shim the axle, then

repeat Steps 11 through 18.

20.Turn the incl inometer of f , then back on ( th is wi i l zero i t to t rue hor izontal) .

NOTE: lf frame rake exists, the measurement that you obtain in the next stepwill be different from the one you obtaineci in Step 18. That measurement wasmaoe relative to the frame rail, while this measurement is beinq made relativeto lrue horizontal.

\rb

PS803035 F.S B. # 3 -00R Page I of 42

Page 10: Peterbilt Rear Air Suspensions Adjustment

21. Remeasure and record the forward rear axle angle (now with respect to the true hori-zontal) at either the top or bottom of the housing, near the axle seat, on the long sideof the axle, with the inclinometer oriented inboard as shown in Figure 9 .

22.Measure and record the rear rear axle angle either at the top of the housing, next tothe axle seat, or at the bottom of the housing, next to the axle clamp, on the long sideof the axle with the inclinometer oriented inboard as shown in Figure 10 .

Figure 10 l l lustration of Using an Inclinometer to Determine Rear Rear Axle Angle

a. For parallel axle configurations: Compare the rear rear axle angle to the forwardrear axle angle you obtained in Step 21 . lf the rear rear axle angle differs by morethan + 0.5 degree, shim the rear rear axle unti l i ts angle is within that tolerance.

b. For broken-back axle configurations: Locate the foruyard rear axle angle (fromStep 21) in the chart for the applicable axle included in this bulletin. Determine ifthe rear rear axle angle is within the range specified for the rear driver. lf value isoutside the range, shim the rear rear axle unti l i ts angle is within that range.

Administrative Notes

Peterbilt will pay for axle angle adjustment on warrantable units as per the establishedlabor rate (Operation No. 032-2 or 033-2 applies).

This bulletin supersedes F.S.B. #3-00R dated March 30, 2001.

Indicates revis ion

Page 1O of 42 F.S.B. # 3-00R PS803035

Page 11: Peterbilt Rear Air Suspensions Adjustment

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Page 14: Peterbilt Rear Air Suspensions Adjustment

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