PREVOST GKN AXLES LIMITED KIRKSTALL DIVISION Service Manual Download Page 65

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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

64A

Hub Inner Bearing Cone

Brake Disc Capscrew

Bearing Nut Pinch Bolt

Hub Bearing Nut

Summary of Contents for GKN AXLES LIMITED KIRKSTALL DIVISION

Page 1: ...ption 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...

Page 2: ...NTS 16 3 FIG 2 REAR SUSPENSION COMPONENTS 16 3 FIG 3 AIR SPRING 16 4 FIG 4 SHOCK ABSORBER 16 6 FIG 5 TYPICAL SHOCK ABSORBER SETUP 16 6 FIG 6 TYPICAL RADIUS ROD SETUP 16 6 FIG 7 RADIUS ROD BUSHING REMO...

Page 3: ...The system operation is fully automatic and maintains a constant vehicle height regardless of load or load distribution The vehicle can also be equipped with systems such as Front kneeling hi buoy Lo...

Page 4: ...ommended body jacking points To gain access to a given air spring the corre sponding wheel can be removed as follows a Jack vehicle until the tire clears the ground and place safety supports underneat...

Page 5: ...empt to raise and lower the bottom portion of each shock Note the rate of effort for distance of travel Replace both shocks if a defi nite differential rate is found The shock must be bench checked in...

Page 6: ...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 fo...

Page 7: ...Lightly Spray the inner and outer surfaces of radius rod bushing with water Caution No lubricant whatsoever is to be used on the rubber bushing 2 Safely support the radius rod and place new bushing on...

Page 8: ...eight between the axle and body is maintained Otherwise the rubber bushings in radius rod ends will become preloaded thus reducing the life of these parts 5 SWAY BAR A sway bar is provided on the fron...

Page 9: ...orming these procedures will allow substandard perform ance to be discovered before the condition be comes bad enough to cause operator complaints and failure on a run 1 Visually inspect the suspensio...

Page 10: ...18 Note The measure should be taken from under the upper air spring support on sub frame to top of the lower air spring support on axle refer to fig 12 for more details If ad justment is required begi...

Page 11: ...tion check for leakage using a soap and water solution 8 2 2 Air Leakage Test Note The following procedure applies when valve assembly has been removed from vehi cle 1 Remove the height control valve...

Page 12: ...tuations In normal con ditions the height control valve is in operation and only the hi buoy can be operated 9 1 Principle of Operation Refer to the system pneumatic diagram annexed in the technical p...

Page 13: ...the technical publication box provided with the vehicle UP The air coming from the control valve on R H lateral console flows through a quick release valve then through double shuttle valves to finall...

Page 14: ...lies air to the front rear right rear left five way three position air control valve which bypasses the front rear right rear left height con trol valve and opens a passage to allow the air control an...

Page 15: ...e 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 e...

Page 16: ...ght control valve as sembly Vehicle body fails to level to satisfactory ride height Improper height control valve over travel lever adjustment Adjust lever as directed 15 PARTS SPECIFICATIONS AIR SPRI...

Page 17: ...30953 SHOCK ABSORBER AND SWAY BAR LINK BUSHINGS Make Monroe Supplier number 45380 Pr vost number 630062 16 TORQUE SPECIFICATIONS 1 Shock absorber pin 350 400 lbf ft 475 545 N m 2 Shock absorber pin nu...

Page 18: ...16 11 2 8 2 Removal 16 11 2 8 3 Installation 16 12 2 9 Steering Arms 16 12 2 9 1 Removal 16 12 2 9 2 Installation 16 12 2 10 Lubrication Fittings 16 12 2 11 Power Steering Hydraulic Pump 16 14 3 INDE...

Page 19: ...ADJUSTMENT 16 28 8 1 Suspension Height Adjustment 16 28 9 HEIGHT CONTROL VALVE 16 30 9 1 Operation 16 30 9 1 1 Loading Position 16 30 9 1 2 Neutral Position 16 30 9 1 3 Unloading Position 16 30 9 2 M...

Page 20: ...17 FIG 14 BALL JOINT 16 19 FIG 15 STEERING LINKAGE MEASURE 16 20 FIG 16 FRONT END ALIGNMENT DIAGRAM 16 23 FIG 17 AIR SPRINGS 16 24 FIG 18 AIR SPRING AND SHOCK ABSORBER 16 25 FIG 19 SHOCK ABSORBER 16...

Page 21: ...d by the steering gear and steering linkage to the steering arms at the right and left front wheels The steering linkage consists of tie rods connected to the bell crank and the steering arm at the le...

Page 22: ...ent in this supplement To check steering maximum turning angle proceed with the following method 1 Check if front tires rub against the frame or if the steering gear has been serviced Caution If clamp...

Page 23: ...Section 16 SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 6 FIGURE 3 CLAMP POSITIONING 16038 FIGURE 4 CLAMP POSITIONING 16039 FIGURE 5 CLAMP POSITIONING 16040...

Page 24: ...Section 16 SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 7 FIGURE 6 CLAMPS POSITIONING 16041...

Page 25: ...s can damage the steering gear Caution Heating of components to aid in disassembly is not allowed because it has a detrimental effect on axle components and steering linkages 3 Remove pitman arm clamp...

Page 26: ...TTINGS at the end of this Supplement 2 6 1 Bell Crank and Idler Arm Removal Note Use a piece of wire to anchor loose end of relay rod and tie rod in order to prevent placing an excessive load on oppos...

Page 27: ...on bearing before in stallation 5 Firmly tighten nut Fig 9 FIGURE 9 BELL CRANK 16044 FIGURE 10 BELL CRANK 16045 6 Unscrew nut until bell crank or idler arm start to turn by the application of 1 to 3...

Page 28: ...m torque Align cotter pin slot tighten and install a new cotter pin 2 8 TIE RODS 2 8 1 Description And Maintenance Tie rod ends are connected to the bell crank and left steering arm and to the idler a...

Page 29: ...ection 13 WHEEL HUBS AND TIRES under paragraph 3 2 Installation of the mainte nance manual 2 10 Lubrication Fittings All lubrication fittings must be clean before applying lubricant Also always be sur...

Page 30: ...bell every 6 250 miles 10 000 km with a good quality lithium base grease NLGI No 2 Shell Retinax LX or equivalent Apply grease gun pressure to the fitting until lubricant ap pears at the top seal FIG...

Page 31: ...e bolt bores are in the correct position in re lation to the axis of the tube 3 Place joint in receiving fixture C and mount annular assembly tool B on the housing Then locate annular spacer 2 and loc...

Page 32: ...Section 16 SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 15 FIGURE 12 BALL JOINT 16047...

Page 33: ...the axis of the tube and that the circlip is properly seated in the housing groove For Pr vost tools refer to table 5 TABLE 3 Suitable for repair kits Pr vost Position Axial load F1 kN 611112 Lower A...

Page 34: ...ORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 17 FIGURE 13 CENTRAL JOINT 16048 TABLE 5 Suitable for repair kits Pr vost ORDER PR VOST TOOLS SEE FIGURE 13 A B C D E G H 611112 683114 683115 683116 68...

Page 35: ...ols refer to table 6 Remove joint bearing elements 1 and 2 and thereafter clean out ball shaped housing 3 3 3 Assembly Reassemble the joint with the new component parts in the following sequence 1 Ins...

Page 36: ...Section 16 SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 19 FIGURE 14 BALL JOINT 16049...

Page 37: ...Section 16 SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION IFS 16 20 FIGURE 15 STEERING LINKAGE MEASURE 16050...

Page 38: ...wheel bearing adjustment 5 Check tie rods and drag link ends for looseness 6 Check king pins for looseness 7 Check if the length of the torque rod is 23 9 64 588 mm Fig 15 Check if the length of the...

Page 39: ...e check toe in 5 Check that the angular relationship of the pitman arm to the steering gear is as shown in figure 7 6 Adjust the drag link to mate with the bell crank and install the drag link Note Us...

Page 40: ...N ON INDEPENDENT FRONT SUSPENSION IFS 16 23 FIGURE 16 FRONT END ALIGNMENT DIAGRAM 16051 DIAGRAM SPECS SEE FIGURE 16 A WHEEL CAMBER 1 8 1 4 B KING PIN INCLINATION 6 5 not adjustable C CASTER 2 not adju...

Page 41: ...ted replace bellow Warning To prevent personal injury do not apply more than 10 psi 69 kPa air pressure with the air spring unmounted 5 2 Removal Note Front air springs can be removed with out removin...

Page 42: ...pplicable then connect air line 4 Connect the height control valve link 5 Build up air pressure in system Note To accelerate this operation air reser voirs can be filled from an exterior air supply co...

Page 43: ...tails 3 Remove the shock absorber from the vehicle 4 Remove inner washers rubber joint and bushings from the shock absorber Dis card bushings and rubber joint FIGURE 19 SHOCK ABSORBER 16054 6 2 Shock...

Page 44: ...55 FIGURE 21 SWAY BAR DRIVE AXLE 16056 7 1 Sway Bar Front Suspension 7 1 1 Removal 1 Disconnect the two links from sway bar 2 Safely support the sway bar Unbolt bushing collars from subframe 3 Remove...

Page 45: ...springs To improve road comfort an expansion air tank is installed in series with each air springs In addition to the above suspension components the system also includes sway bar upper and lower susp...

Page 46: ...t 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 CLEA...

Page 47: ...Remove the nuts retaining the height control valve to the mounting bracket then remove valve assembly Reverse removal procedure to replace height control valve After installation check for leakage usi...

Page 48: ...drain valves at specified intervals This tank is installed above L H wheel of drive axle and is provided with a bottom drain valve It is recommended to purge the wet air tank by its bottom drain valv...

Page 49: ...a year whichever comes first A remote drain valve is located in steering com partment Fig 28 at bottom of the accessory air filter Refer to Section 12 paragraph 4 Acces sory Air Filter of the mainten...

Page 50: ...ly line The rear valve will supply air for all systems brakes suspension and accessories while the front valve will supply air for accessories only Caution Air filled through these two points will pas...

Page 51: ...lications as well as harsh braking 13 BRAKE AIR CHAMBER The front wheels are equipped with Knorr Bremse brake chambers used for service brake 13 1 Maintenance Refer to maintenance manual Section 12 pa...

Page 52: ...80 80 108 Steering Arm to Swivel Nut 4 190 275 258 373 Torque Rod Stud Nut 2 4 160 215 217 291 Idler Arm and Bell Crank Mounting Bracket Nut 8 5 100 110 136 149 Idler Arm and Bell CrankCap Screws 8 9...

Page 53: ...upplier number 1R12 377 Pr vost number 630151 Shock Absorbers Collapsed length 14 20 inches Extended Length 22 45 inches Piston diameter 2 1 16 inches Stroke 8 inches Pr vost number 630136 Height Cont...

Page 54: ...GKN AXLES LIMITED KIRKSTALL DIVISION SERVICE MANUAL FOR AXLE TYPE S82 HUB UNIT AND SWIVEL ASSEMBLY FITTED TO PR VOST S XL CONVERTED COACH SHELL WITH INDEPENDENT SUSPENSION REVISED BY PR VOST CAR INC...

Page 55: ...ABLE 8 10 PARTS LIST 9 LIST OF ILLUSTRATIONS FIG 1 SWIVEL GREASING POINTS AND HUB OIL LUBRICATION 2 FIG 2 METHOD OF CHECKING SWIVEL BEARING ADJUSTMENT 4 FIG 3 TOP AND BOTTOM CAP 5 FIG 4 PART SECTION T...

Page 56: ...acking of the hubs A sight glass is provided for convenient check of oil level Oil level should be checked daily and must be maintained to the level mark in the sight glass If oil is not visible throu...

Page 57: ...inner bearing cone 11A Fig 8 from hub 8 Fig 8 12 Drive out hub bearing cups 11 64 Fig 8 from hub 8 Fig 8 13 If hub bearing distance piece oil seal wear sleeve 60 Fig 8 shows signs of wear or corrosio...

Page 58: ...cate swivel pin bearing sleeve 17 Fig 8 with clean oil grease then fit over protruding swivel pin 56 Fig 8 large chamfer first to locate in oil seal bore 18 Fig 8 and abut upright 37 Fig 8 3 Select sw...

Page 59: ...complete 1 8 bead of Loctite Superflex black around base of bottom cap 55 Fig 8 before fitting to swivel 58 Fig 8 within 5 minutes of applying Loctite See figure 3 FIGURE 3 TOP AND BOTTOM CAP 10018 5...

Page 60: ...her and hub bearing nut 6 67 Fig 8 Tighten nut hard with the aid of a small tommy bar just enough to take up bearing slack 8 Fit hub bearing nut pinch bolt and nut 66 5 Fig 8 tighten finger tight 9 Ad...

Page 61: ...table chlorinated solvent then apply a complete 1 8 inch bead of Loctite Superflex black around mating face of hub cap 3 Fig 8 See figure 7 FIGURE 7 HUB CAP AND HUB MATING FACES 10022 12 Fit hub cap a...

Page 62: ...0 340 420 461 22 Swivel Pin Nut 500 700 678 949 25 Top Cap Setscrew 51 62 69 84 28 Top Steering Arm Stud 190 210 258 285 30 Top Steering Arm Nut 190 275 258 373 31 Caliper Bracket Nut 85 103 115 140 4...

Page 63: ...Bearing Cup 2 11A Hub Outer Cone 2 12 Hub Oil Seal 2 13 Brake Caliper R H 1 Brake Caliper L H 1 14 Caliper Mounting Bracket R H 1 Caliper Mounting Bracket L H 1 15 Brake Caliper Retaining Washer 12 16...

Page 64: ...d R H 2 29 Top Steering Arm L H 1 30 Top Steering Arm Nut 4 31 Brake Caliper Bracket Nut 6 32 Stop Screw Adjusting Washer as required 33 Swivel Stop Screw L H 1 Swivel Stop Screw R H 2 34 Supplied Wit...

Page 65: ...wivel Assembly R H 1 59 Brake Caliper Bracket Stud 10 60 Hub Bearing Distance Piece 2 61 Brake Caliper Bracket Bolt 6 62 Brake Caliper Bracket Nut 10 63 Brake Disc 2 64 Hub Inner Bearing Cup 2 64A Hub...

Page 66: ...12 FIGURE 8 HUB UNIT AND STUB AXLE 10023...

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