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1. A A A ee Fr T7 Shim Pack 1 jH Shim Pack 2 CENTER AXLE The center axle of the suspension is easier to align Adjust the alignment by moving the leaf spring eye pivot in the slot of the rocker beam fore and aft to get alignment before torqueing the pivot bolt Once you have alignment torque the pivot bolt and add a weld top and bottom of the round bearing boss to help hold alignment Alignment Axle Spacing Cush has several different axle spacing s available for different applications See your Cush installation drawing for your application Axle Equalization For Closest Axle Equalization the Trunnion and Axle Centers Must Be on Same Horizontal Plane When Vehicle is Fully Loaded Install Soacers at Frame Brackets to Achieve This NOTE The axle spacing will be measured with the trailer unloaded The axle spacing and ride height will decrease as the suspension springs are loaded and defect up Page 9 Giving the World a Better Ride eee ae a CushWALKER SUSPENSION SERVICE MANUAL 5 00 j Axle Seat o pw Q cy nC PX a no f R Te eee 5 Bag i RefCam F YS 9 04 Min Ride Height Position Alignment A 3 62 5 50 Axle Spacing B 50 Axle Spacing 75 75 Trunnion Tube Spacing Axle Welding Installation Notes e Customers may have different axle tracks and applications that will dictate the center spring beam spacing to mount the axle seat to t
2. 4c amp 4d Remove remaining of bolt 4a do this on both sides of axle Pull axle off of end of Compensator tubes Remove snap ring from axle seat Remove bushing Check housing for any damage CON OF B amp B W PO Note4 Removal of Trunnion Bushing in Compensator 1 Remove axle seats axle from Compensator to be worked on 2 Remove Spring from other end of Compensator 3 Move axles and tires out of the way 4 Pull Compensator off of trunnion tube 5 Remove snap ring 6 Remove bushings 7 Check housing for any damage CushWALKER SUSPENSION SERVICE MANUAL Installation and removal of RUBBER Type Trunnion amp Axle Seat Bushing Installation Notes 1 IMPORTANT Tire Lube the inside of the bushing tube housing and outside of rubber bushing wipe so that it is spread evenly 2 Insert rubber bushing center in housing 3 Install bushing into housing Page 16 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Spring Pivot Bushing Component Replacement The pivot of the eyed leaf spring allows for more articulation and softer ride characteristics than a steel spring walking beam This pivot bushing is made of rubber compound to effectively absorb loads and maintain its shape In order to use standard off the shelf replacement components bushings may require insert reducers to allow for spacing offsets and to accommodate smaller bolts th
3. be involved to complete the warranty repair Shop per hour labor rate allowances will not exceed standard industry averages for the work done Warranty claims should be filed per the CushWALKER Warranty File with an itemized list of charges and copies of all available receipts NOTE Get written approval warranty estimate from Cush Corp before working on item that you would like to submit for a warranty claim Failure to do so may eliminate your warranty claim OCT 08 2014 IUS Page 6 a Giving the World a Better Ride Baa J CushWALKER SUSPENSION SERVICE MANUAL Suspension Installation ltems In Service Axle Alignment General Notes Cush has several different alignment means available for different applications Listed here are some general alignment guidelines and alignment procedures for the styles of Cush Alignment CAUTION DO NOT APPLY undercoating to the pivot alignment area until after alignment and torque of the suspension pivot bolts e Check that the tire inflation pressure is correct on all tires e Alignment should be performed with the vehicle empty and the brakes released e Ona level floor move the vehicle forward and back to straighten make sure last movement is forward e Remove the outer tires and any other parts from under the chassis that obstruct the measuring distances between the kingpin and the axle ends If you use a commercially available kingpin and axle spindle extenders or the edge of the
4. of both suspension axle seats e Position and weld rear root pass Do not wrap welds over axle seat ends no weld 19 from ends Weld rear 2nd amp 3rd cover pass Position amp weld front root pass Weld front 2nd amp 3rd cover pass e Weld axle seat side welds Note Once the welds are cool mount the u bolts and spring Torque the u bolts for the axle seat to the spring Page 12 Giving the World a Better Ride ee aera CushWALKER SUSPENSION SERVICE MANUAL O O U BOLT INSPECTION amp INSTALLATION NOTES CAUTION Do not apply any additional lubricants to the u bolts improper clamp loading can occur causing failure Inspection Check each U bolt threaded area for damage or burrs After installation an equal amount of thread should be visible beyond the head of the nut on each side of the U bolt Installation O U Bolts should only be installed and torqued after completion of any axle welding Allow sufficient axle cooling time before applying torque to u bolts Check that U bolts fit properly in area if U bolt is to tight tap on top of U bolt to hard surface to open up Be careful that U bolt installation does not damage threads Snug all U bolts evenly before applying clamping torque with hand wrench Check that u bolts are parallel and square to axle Torque U bolts in a three step process to avoid an improperly clamped axle and resulting damage Torque the u bolts in an X pattern with eac
5. or contact Cush Corp for cross reference Lubricate outside of new Cush bushing and inside of spring eye bushing sleeve with proper rubber lubricant P 80 or Ru glyde Put bushing into bushing insertion tool to reduce bushing from free OD to smaller OD of spring eye Lubricate tool before placing bushing Press in bushing try to center inner metal bushing sleeve with the outer metal bushing housing it may be necessary to push bushing thru a little and pull back to center rubber and inner metal sleeve Reassembling pivot connection If required replace the flanged inserts from to the inner diameter of the bushing tube sleeve If these inserts are loose and do not stay in place you may need to hold these inserts while guiding the spring into the compensator walking beam hanger Note it is easier to do this with the compensator on the ground upside down and use gravity to lower the spring eyes into the compensator Center the spring eye with inserts at the compensator pivot slot use a tapered rod to assist Gather the alignment gear hardware and new fasteners to remount the pivot Hand tighten the pivot hardware to hold the position of all loose items If needed to spread the compensator hanger using a hydraulic jack or other spreading device spread open the compensator until flanges of flanged inserts enter the inside of the compensator remove spreading device Place adjustment gear per suspension drawing Always use new fastene
6. torquing fasteners could result in material failure Torque chart TORQUE SPECS Min Max Min Max Pieseription ets tems e ne 7 8 14UNF Ubolt and Nut Axle Ubolt 475 525 644 712 1 2 13UNC Grade 8 Button Head and Toplock Nut for Bolt in Keeper Pin 80 110 108 149 3 4 10UNC Grade 5 HHCS and Center Lock Nut for Trunnion Hanger 210 235 285 319 Page 5 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Customer Welding Notes e tis the responsibility of the suspension installer and vehicle designer to provide adequate vehicle frame design gusset support in the area of Suspension attachment and proper securing method for the suspension system The suspension installer has the responsibility to determine the proper welding parameters for the materials being used For specifications of suspension component materials contact Cush e Required vehicle support cross member locations may be shown Actual size and shape may vary per trailer design It is the responsibility of the suspension installer to ensure structural adequacy of the trailer frame and related cross members e No welding of any of the suspension components is permitted except where specified by Cush e Any alteration of the suspension components or installation deviations must be approved in writing by Cush Corporation Recommended Steel Welding Procedures If Required e WARNING I
7. wheel rim you will not need to remove this equipment e Measuring from the trailer s kingpin determine the alignment of the forward axle e After achieving proper alignment of the forward axle torque the Cush Pivot fasteners per Cush torque specifications see Cush Axle Alignment procedures in this manual e Align the next axle to within 0 1 tolerance amp any additional axles to the forward axle per the proper alignment method Use a commercially available alignment gauge or trammel bar if available See Figure 2 AN KINGPIN TANG 418 npn tf 171867 NOTE Failure to follow the procedure for your axle alignment application and or properly torque the pivot fasteners can result in a failed pivot connection and a loss of warranty coverage Installation Axle Alignment on CushWALKER To align the axles at installation first the trunnion tubes of the suspension should be aligned to the kingpin before they are welded in place Page 7 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Torque Specs Size Description Min ft lbs Max ft lbs 3 10UNC Grade 5 AACS and Center Lock Mut for Trunmion Hanger 210 235 e Center the Trunnion tube frame hangers on the tube per the spring centers e Torque the 3 Trunnion tube bolts to 220 ft lbs e Align Front Trunnion to Kingpin by Shifting Trunnion Clamp on Frame Bracket Tack Weld in Place once trunnion tube is aligned on each end a
8. CUSH CORP Mechanical Walking Beam Suspension Model CushWALKER Tri Axle Suspension Installation amp Product Service Table of Contents Model Specific Service and Installation Manual e Cush Model CushWALKER Description e Installer Responsibility Inspection Schedule e Trailer Structure e Original Inspection e Daily Inspection 30 amp 90 day Inspection e Axle Alignment Inspection e Axle Inspection Suspension Maintenance Items e Caution Notes e Torque Specifications e Customer Welding Notes e Warranty Note Suspension Installation Items e Axle Alignment e Axle Seat Welding e Pivot Components e Suspension Trunion Hanger Mount Service Appendixes e Typ Suspension Parts Explosion Drawing e Typ Application Drawing Cush Corp 1001 Falconcrest Ct Nixa Mo 65714 Page 1 Phone 417 724 1239 Giving the World a Better Ride Pub 100814 Rev 0 Fax 417 724 0126 OCT 08 2014 www cushcorp com CushWALKER SUSPENSION SERVICE MANUAL Model CushWALKER CSTR Description This model is designed to work with oscillating axle end seats to allow more suspension articulation and a better ride than rigid walking beam or spring leaf walking beam single point suspension This model can be with all rubber bushings or upgraded to urethane bushings at the oscillatory spots for more articulation requirements of military applications or severe service The CushWALKER model is designed to have several advantage features over co
9. ING If these procedures and specifications are not followed damage to the axle or suspension could result The resulting axle or suspension damage could cause an accident property damage and or serious injury NOTE A welder qualified in 2G position per ANSI AWS D1 1 94 Section 5 Part C Welder Qualification must perform the welding NOTE The specification shown below is for horizontal 2F positioning 1 Suspension components and their mating parts must be at a minimum temperature of 60 F 15 5 C and free from moisture dirt scale paint grease and other contaminates Pre heat per axle manufacturer 2 All welds must be performed in a flat or horizontal position Clean welds between each pass Standard Wire AWS ER 70S 6 0 045 DIA Volts 26 30 DCRP Current 275 325 AMPS Gas 90 AR 10 CO2 at 30 to 35 CFH Note Brake camshaft to be located according to axle manufacturer specifications amp suspension trailer model Use locating fixture or flat surface to space suspension axle seats and center axle Check that axle seats are parallel square to axle and perpendicular to axle e The suspension axle seat must be tight against the axle tube with no more that 063 gap at bottom e Weld sequence size and weld direction should be followed for proper installation e Back weld 38 over the start ends of all welds e Fill all craters avoid cold laps and undercuts e Place 1 2 tack welds in the center forward of both susp
10. at can be properly torqued to their effective 90 of proof load Tools required Shop wrenches bushing press bushing insertion tool per unit Disassembling Pivot Connection of Cantilever Spring e On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height Support the weight of the walking beam underneath the center Remove tires from the side that you will be removing the cantilever springs Loosen and remove pivot hardware from spring side to be replaced Inspect pivot connection area of compensator after removing spring If spring is to be placed in shop press you will need to remove each from the axle connection remove u bolts grind away axle seat connection welds between bottom seat and top seat leave axle welds connecting top seat to axle in place take apart axle seat top and bottom to be able to remove spring leaves from bottom seat dowel pin e Some models remove the flanged inserts from the inner diameter of the bushing tube e Take spring to shop press and remove old bushing e Clean debris from spring eye cavity ATUNIMIN NON ULLAL MM GY95 9 a dhddtileds Center Bushil Bushing Insert Tool p n C0246 K E ras KILL ANAAL BRRR RAAG Page 17 Giving the World a Better Ride E a CushWALKER SUSPENSION SERVICE MANUAL Bushing Replacement Use Cush bushing replacement kit shown on parts explosion for your Suspension
11. em is designed to minimize service issues With proper maintenance the life of your Suspension system can be extended Caution Notes e Trailer walk can occur due to loading unloading or damaged parts e For safe loading and unloading leave trailer attached to vehicle e Do not tow or pull on vehicle by suspension components e Fasteners that have been in service should never be reused over torqued or lubricated Do not operate vehicle suspension with e Broken welds or metal parts e Loose broken or missing fasteners or suspension components e Loss of air pressure in brake system Torque Specifications It is the customer s responsibility to check and tighten fasteners to specified torque at installation after the suspension has been in operation for 3000 miles and at suspension inspection cycles Failure to do so can result in loss of warranty CUSTOMER TORQUE INSTRUCTIONS 2 It is the customer s responsibility to check and tighten fasteners to specified torque at installation after the suspension has been in operation for 3000 miles and at suspension inspection cycles Failure to do so can result in loss of warranty 3 Torque values given are specified for the fasteners in the condition supplied by Cush Corporation DO NOT APPLY ANY ADDITIONAL LUBRICANTS 4 CAUTION Fasteners should never be reused if removed or complete loss of clamp load occurs For proper joint clamping contact Cush for replacement fasteners 5 CAUTION Over
12. ension axle seats e Position and weld rear root pass Do not wrap welds over axle seat ends no weld 19 from ends Weld rear 2nd amp 3rd cover pass Position amp weld front root pass Weld front 2nd amp 3rd cover pass e Weld axle seat side welds Note Move back and forth to allow welds to cool and minimize distortion You can skip in a X pattern for the axle welding Page 11 Giving the World a Better Ride E as a CushWALKER SUSPENSION SERVICE MANUAL Suspension to U bolted Axle Seat Welding Procedures Note the same welding parameters required as on front and rear axle seat On the tri or quad axle version of the CushWALKER the mid axles are mounted to a leaf spring with u bolts and an axle seat for a 5 round axle 5 8 wall min required After the axle alignment is checked these axle seats have a fore and aft edge that get welded to the axle with a 3 pass weld this weld edge seam is at least 3 long Use locating fixture or flat surface to space suspension axle seats and center axle Check that axle seats are parallel square to axle and perpendicular to axle e The suspension axle seat must be tight against the axle tube with no more that 063 gap at bottom e Weld sequence size and weld direction should be followed for proper installation e Back weld 38 over the start ends of all welds e Fill all craters avoid cold laps and undercuts e Place 1 2 tack welds in the center forward
13. f these procedures and specifications are not followed damage to the axle or suspension could result The resulting axle or suspension damage could cause an accident property damage and or serious injury e A welder qualified in 2G positions per ANSI AWS D1 1 94 Section 5 Part C Welder Qualification must perform the welding e The specification below is for horizontal 2F positioning e Suspension components and their mating parts must be at a minimum temperature of 60 F 15 5 C and free from moisture dirt scale paint grease and other contaminates e All welds must be performed in a flat or horizontal position Achieve spray arc transfer with the following welding parameters e Standard Electrode AWS E 7018 Oven Dried 0 125 DIA 120 140 AMPS D C Electrode positive Standard Wire AWS ER 70S 6 or AWS ER 70S 3 0 045 DIA Volts 26 30 DCRP Current 275 325 AMPS Wire Feed Speed 380 420 Inches per Minute Electrode Extension 0 75 to 1 Gas 86 AR 14 CO2 at 30 to 35 CFH Any deviation from these welding parameters must be of equal strength or approved by Cush Corporation in writing Warranty Note lf after review of the Cush Corp Warranty it is determined that there is a warranty issue and Cush Corp has been notified then a Warranty Labor Allowance may be needed The WLA for the following service items are shown with each itemized description The service item descriptions include the obvious parts involved other parts may
14. following e The axles have been aligned properly The suspension frame bracketry have been properly supported Trailer is level All welds are of good and acceptable quality All fasteners are in place and securely torqued No component interferences are visible There should be 1 minimum clearance between top of tire and bottom of trailer structure when axle is at full jounce If not a bump stop will need to be added 7 USE i Page 3 Giving the World a Better Ride E i CushWALKER SUSPENSION SERVICE MANUAL e There should be 2 minimum clearance between inside of tire and trailer frame structure for lateral movement e There should be ample fore and aft clearances Daily Inspection A quick visual inspection before operating the trailer will often detect obvious problems such as broken or loose parts CushWALKER 30 day Inspection Check clearances around all moving suspension parts such as springs tires axle seats u bolts fasteners and compensator for any signs of wear loosening or component interferences Check each of the following Fasteners Not loose broken or missing retorque if needed Pivot Bushings Not protruding off center torn or worn Frame Hangers Not worn cracked bent or damaged Compensator Not worn cracked bent or broken Cantilever Springs Not cracked bent out of alignment or loose Axle Beam Not cracked bent or broken Tires No tire wear that might indicate an a
15. grinder do not gouge frame Raise the new hanger assembly to the frame and clamp hanger to frame squarely Align hanger assembly to kingpin see Hanger Alignment notes Weld hanger to frame per Cush Corp installation drawing Reassemble any other parts that were disassembled to lower assembly Align axles with relation to the kingpin see Axle Alignment Torque all the fasteners to specification Apply paint to prevent rust corrosion Page 19 Giving the World a Better Ride E eras ta CushWALKER SUSPENSION SERVICE MANUAL Parts Explosion Urethane Bushings Use Silicone Grease on All Bushings vO Shim Pack 2 PARTS LIST DESCRIPTION X Ig 3 5 OD Trunnion Tube Trunnion Hanger Clamp Compensator Arm with Urethane Bushing and Snap Rings Axe Seat Pedestal with Urethane Bushing and Snap Rings 5 JAco502 JE E oring with Rubber Bushing 6 Wiie9 Bolt In Keeper Pin 7 Wi162 Ake Spring Seat 8 wi163 Spring Gamp Plate 9 JAT0i93 o HiT Sleeve with Rubber Bushing Tio 0375 4 vot Bok Hardware 44 Bolts 11 K0630 4 Axle Seat Trunnion Shim Pak 43 K03744 Ade UboltKit X4Bolts ti 14 K0378 4_ __ Trunnion Hanger Fasteners X8 Bolts 1 Page 20 Giving the World a Better Ride E eee i CushWALKER SUSPENSION SERVICE MANUAL Parts Explosion Rubber Bushings TEM PARTS LIST 2 W1163 Spring Clamp Plate Ea ATO193 Bushing Sleeve with Bushing 9 KO375 4 Pivot Bolt Hardware
16. h torque step 1 2 3 4 This allows the U bolt to stretch and relax for the clamp to hold torque Proper tightening will allow equal amount of tread above each nut Use a calibrated torque wrench to get the proper setting for the size of U bolt you are using P o First Step 1 3 of Final torque S a 4 o Second Step 2 3 of Final torque A Si y 30 a AUT o Third Step Final torque fs Pane Te ee Nep After U bolts have been torqued spec weld bottom plate gussets sides to side of spring end box to secure that cantilever springs do not delaminate Use 3 long welds Sr Rekber Bushrg WNIT hd Clamp Hate 7 3 1 EE Stordon Heich Hut Page 13 Giving the World a Better Ride E a CushWALKER SUSPENSION SERVICE MANUAL Trunion Pivot Component Replacement The pivot of a trunion hanger on a mechanical suspension is the main link to connect the suspension to your trailer This link provides a resilient connection that allows a walking beam or compensator to walk without excessive flexing Re bushing does not require a shop press wa General notes Disassembling trunnion Pivot Connection of walking beam e On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height Support the weight of the walking beam Remove tires so that you can lower walking beam with axles from trailer Loosen and remove any nuts bolts and springs restricting movement of walk
17. he axle e Spring seats may be pre welded to axles prior to assembling to other suspension components see Cush installation drawings Note cam shaft clocking when welding axles e Customers should also determine the clocking of the cam relative to the suspension axle seat Customers may want to vary this per their application e Note Customers must check that cam slack placement will not cause interference with trailer components during articulation causing part failures e See picture below to locate cam shaft positions Try to put the push rod of the brake chamber so that it pushes on the brake slack adjuster the same rotation as the tire rotation moving forward motion This will help reduce brake hop Fig of suspension layout side view showing cam shaft locations Ref Cam Min Position 1 4 Axle Ride Height Alignment Page 10 Giving the World a Better Ride eee a ta CushWALKER SUSPENSION SERVICE MANUAL Suspension to half round Axle Seat Welding Procedures On the tri or quad axle version of the CushWALKER the front and rear axles are mounted to the suspension with a weld on half round axle seat for a 5 round axle 5 8 wall min required After the axle alignment is checked these axle seats have a fore and aft edge that get welded to the axle with a 12 3 pass weld this weld edge seam is at least 9 long The axle should be preheated before welding RECOMMENDED STEEL WELDING PROCEDURES WARN
18. hing 2 onto trunnion tube 1b 5 Utilize installation kit KO383 to pull bushing 8b and Compensator 2 onto the trunnion tube at the same time Do this with installation caps all thread and 1 air impact 6 After Compensator with bushing is fully installed install outer snap ring 3b into housing 7 Perform same procedure on opposite side Note2 Installation of axle seat housing trunnion bushing 1 Place inside snap ring 3c into Axle Seat Housing 8a 2 Silicone grease the inside of the bushing housing 3a outside of Compensator Equalizer Beam tube 1b and inside of bushing 3b 3 Insert trunnion bushing 3b into housing 3a 4 Place outside snap ring 3c into Axle Seat Housing 3a 5 Mount alignment shim pack 1 2x4c amp 2x 4d 6 Start the mount of housing with bushing 3 onto end of greased tube 2a 7 Use installation tool kit KO384 to pull axle seat onto tube 8 After installed all the way mount the remaining shim pack 4c amp 4d for later alignment make sure there is a gap of 0 063 to allow rotation If not remove shims so that there is the proper gap 9 Mount Bushing end cap 4b and end bolt 4a thread bolt in without cross threading 10 Use E 20 socket to torque bolt 4a and shear of torx nub to get proper torque of 500 600 ft lbs Note3 Removal of axle seat housing trunnion bushing 1 Remove end cap bolt 4a may have to cut off bolt head with torch Remove end caps and shims 4b
19. ing beam Remove the end axle seats amp axles from walking beams e Pull walking beam from trunion tube e Inspect trunion housing and trunnion tube area for any metal damage that could tear a new bushing e Clean trunion area of any dirt or grime build up e lf is rubber no lubrication needs to be added e f bushing is urethane add a thin coating of silicone grease around trunion tube area Urethane bushings are used to allow freer articulation of the walking beam e For rubber or urethane bushing a new bushing might come without a slit with a box knife cut a straight line on the bushing horizontal place the bushing on the trunion tube with the slit on horizontal centerline and centered in hanger e Reinstall the new bushing e Reinstall walking beam on trunnion tube using all thread tool Cush p n K0383 80 or a hydraulic cylinder kit p n AW1286 to pull the walking beam back onto the trunnion tube Page 14 Giving the World a Better Ride E ia CushWALKER SUSPENSION SERVICE MANUAL Installation and removal of URETHANE Type Trunnion Bushing Procedure K0382 Notel Installaion of Urethane Trunnion Bushing Compensator onto Trunnion Tube 1 Place inside snap ring 3c into Compensator 2a 2 Silicone grease the inside of the bushing housing 2a outside of trunnion tube 1b and inside of bushing 3b 3 Insert trunnion bushing 3b into Compensator housing 2a 4 Start the mount of Compensator with bus
20. ions on all the drawing sheets thoroughly before proceeding with a suspension installation 5 If additional lateral support is needed for the suspension it is the responsibility of the suspension installer to install rub guides to support the appropriate load for your application Contact Cush with questions about lateral support guides Page 2 Pub 100814 Rev 0 OCT 08 2014 CushWALKER SUSPENSION SERVICE MANUAL 6 If Axle Stops Are Required the Trailer Manufacturer Must Provide a Design sufficient to Distribute Loading on Axle and Suspension Frame Reinforcements May Be Required Inspection Schedule The following inspection schedule is a guide to help with the preventative maintenance of your Suspension system Your mechanical suspension will provide many trouble free miles of service by using the information in this publication QC CushWALKER Hanger Pre Welding amp Alignment o Verify that you have the correct height and width hangers for your application o Before welding the suspension straddle mount trunion hanger to the frame you need to first measure that the center of the trunion tube is aligned to the kingpin of the trailer Measure to the outer edge center of the trunion tube Also verify that the trunion hanger is centered on the frame Ot ___ qed QC CushWALKER Original Inspection After Installation When reviewing the suspensions on your trailer for the first time check the
21. lignment problem Axle Alignment No pivot gear movement or inappropriate wear axles tracking properly e Trailer Trailer not leaning trailer frame suspension attachment structurally sound no cracked or missing welds at suspension frame attachment CushWALKER 90 day Inspection and at every brake lining change Thoroughly check all items checked at the 30 day inspection Also check e All welded connections for signs of deterioration e All frame attachment joints and pivoting or clamping joints for problems retorque e All spring eye bushings intact e For any sagging or broken leaf springs CushWALKER Axle Alignment Inspection Check the Cush Align connection for change of position at 30 day 90 day and every brake lining change Re align if necessary Re tack the alignment gear of the center axle after adjustment to maintain position in heavy duty applications Axle Inspection general notes see axle manufacture s service manual for details Visually inspect the all axle components seals and hub caps for leaks and oil level every 6 000 miles if oil bath type Repair if necessary At 100 000 miles or 12 months visually inspect seal and hub cap for contaminants oil level or leaks Check the wheel bearing adjustment Repair amp retorque if necessary Page 4 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Suspension Maintenance Items The Cush trailer suspension syst
22. mpetitive units alignment adjustment on the axle heavy duty hanger and rocker components industry standard replacement pivot bushing common replacement bolts rubber or urethane trunion bushing heavy duty keeper sleeves replaceable spring seat wear pads low profile compensator structure Installer Trailer Structure Responsibility INSTALLATION DISCLAIMER NOTES 1 It is important that the proper Cush suspension is chosen for the trailer application The following criteria must be considered when selecting a Suspension required suspension capacity loaded frame to ground measurement ride height axle travel axle spacing and axle GAWR 2 It is the responsibility of the installer to determine the correct location of the Suspension in order to provide the proper trailer load distribution The gross axle weight rating GAWR of each axle must not exceed the rated capacity of any of the components involved The suspension capacity ratings are for suspension components and axle beam only 3 Required frame hangers bump outs supports and cross member locations maybe shown Actual size and shape may vary per trailer design It is the responsibility of the suspension installer to ensure structural adequacy of the trailer frame and related cross members Verify that the actual trailer cross member locations correspond with those specified on the suspension drawing 4 It is the responsibility of the suspension installer to read the instruct
23. nd side to side e Align Rear Trunnion to Front Trunnion in Same Mannor Tack Weld in Place e Check alignment on both Trunnion tubes e Weld Trunnion Clamps Securely in Place After Final Axle Alignment Installation Axle Alignment lf the trunnion tubes are aligned but the axles are still not aligned then start by aligning the front axle to the kingpin at the axle seat FRONT amp REAR AXLE If this is a new installation and the end cap ring has not yet been installed you can remove the axle seat and shims can be shifted from one side of the axle pedestal to the other for axle alignment You can align the axle seats to the kingpin prior to installing and welding in the axle for ease of alignment Maintain a 1 64 to 1 16 gap in the shim pack Adjust the shims so that the front axle is aligned to the trailer kingpin to within 1 8 Install the axle and check the alignment If the alignment is still off you can grind out of the axle seat to give you room to adjust the axle alignment Set the alignment and tack the axle in place Weld the end cap ring in place on the end of the beam tube after alignment Weld the axle in place Page 8 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Shims can be shifted from one side of axle pedestal to other for 3 8 axle alignment Use as many shims as possible but maintain 1 64 to 1 16 gap in shim Pack 2 Nag Ih PA yw yr 4 lt After Axle EE iee
24. r hardware Using a wrench move alignment gear pointers to nominal position Align axle with relation to the kingpin per Axle Alignment notes Torque all the fasteners to specification Page 18 Giving the World a Better Ride E CushWALKER SUSPENSION SERVICE MANUAL Suspension Frame Hanger Cush manufactures various hangers for different applications because of this it would be best for you to contact Cush for an installation drawing per your application On these drawings we may show recommended cross member and support locations your trailer manufacture may have an installation drawing for this Failure to have the proper support in place can cause a reoccurring failure mode If for some reason it is required to replace a frame hanger please follow the guidelines below as a minimum safety procedure when repairing these items G SI D To replace welded frame hanger e Contact your trailer manufacturer or Cush Corp for replacement parts On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height Remove Tires as required Disassemble the pivot connection and any other parts that interfere with lowering the walking beam out of the suspension hanger Lower the assembly check for any damaged or wear Check that the bushings are in usable condition Mark the hanger position on the frame side for reference Cut away the frame hanger and clean up the frame with
25. x4 Bolts KO630 4 Axle Seat Trunnion Shim Pack 1 KO3 7 Keeper Pin Fasteners at Compensator KO374 4 Axle U Bolt Kit x4 Bolts F1138 19 3 16 Shim Plate Giving the World a Better Ride Page 21 Pub 100814 Rev 0 OCT 08 2014

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