OTC 4246, 4247 Instructions Manual

Explanation of Safety Signal Words

The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Safety Precautions

WARNING: To prevent personal injury and/ or property damage,

•

Study, understand, and follow all safety precautions and operating instructions before using

this Hendrickson Rear Suspension Bushing Tool. If the operator cannot read instructions, operating instructions and safety precautions must be read and discussed in the operator’s native language.

•

Only qualiﬁed operators may install, operate, adjust, maintain, clean, repair, inspect, or

transport this suspension bushing tool.

•

Wear eye protection that meets ANSI Z87.1, CE EN166, AS/NZS 1337, and OSHA standards.

•

Do not use this suspension bushing tool for anything other than its intended purpose.

•

No alteration shall be made to this product.

•

Inspect the condition of the suspension bushing tool before each use; do not use if damaged,

altered, or in poor condition.

•

Use only those repair parts called out in the parts list in this document. Items found in the

parts list have been carefully tested and selected by OTC.

Hose

•

Before operating the pump, tighten all hose connections using the correct tools. Do not

overtighten; connections need only be secure and leak-free. Overtightening can cause premature thread failure or high pressure ﬁttings to split at pressures lower than their rated capacities.

•

Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut OFF the pump, and open the control valve to release all pressure. NEVER grasp a leaking, pressurized hose with your hands; the force of escaping hydraulic ﬂuid could cause serious injury.

•

Do not subject the hose to any potential hazard such as ﬁre, extreme cold or heat, sharp

surfaces, or heavy impact. Do not allow the hose to kink, twist, curl, or bend so tightly that the ﬂuid ﬂow within the hose is blocked or reduced. Do not use the hose to move attached equipment. Periodically inspect the hose for wear, because any of these conditions can damage the hose and result in personal injury.

•

Hose material and coupler seals must be compatible with the hydraulic ﬂuid used. Hoses

also must not come in contact with corrosive materials, such as creosote-impregnated objects and some paints. Consult the manufacturer before painting a hose. Never paint couplers. Hose deterioration due to corrosive material can result in personal injury.

Pump

•

Do not exceed the maximum capacity of the pump or tamper with the internal high pressure

relief valve. Creating pressure beyond the rated capacity can result in personal injury.

•

Completely retract the cylinder before opening the ﬁller screw on the pump to add hydraulic

ﬂuid. An overﬁll can cause personal injury due to excess reservoir pressure created when cylinders are retracted.

Cylinder

•

Do not exceed the maximum capacity of the cylinder. Creating pressure beyond the rated

capacity can result in personal injury.

•

Adapters must be aligned and fully engaged so cylinder force is straight, avoiding an off-

center load condition.

1

HENDRICKSON COMFORT AIR® – Pivot Bushing Removal

HENDRICKSON COMFORT AIR

Pivot

Bushing

Pivot Bushing Removal

1.

Insert the adapter pin through the alignment tool and into the pivot bushing hole as shown in Figure 1.

2. Place the clamping plate over the alignment tool.

3. Assemble the clamping nuts to the threaded rods.

®

Remove

Install

Threaded

Rod

575164 Saddle

Adapter Pin

575163

Adapter

4 4 4

4 4

576421

D-Pin

Adapter

Alignment

Tool

Head Plate

575165

Bushing

Support

Hex

Nut

575167

Alignment

Tool

4. Insert a threaded rod through the upper holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

5. Insert a threaded rod through the lower holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

6. Tighten the clamping nuts to the clamping plate. See Figure 2.

7. Remove the alignment tool and adapter pin.

Clamping Nut

Remove the

Alignment Tool

and Adapter Pin.

Clamping

Plate

Figure 1

Illustration showing the

assembly after steps 1 – 6.

Figure 2

2

HENDRICKSON COMFORT AIR® – Pivot Bushing Removal

Cylinder

Mounting Plate

Hex Nut

Cylinder

D-Pin

Adapter

Figure 3

Adapter Pin

Pivot Bushing Removal contd.

8. Thread the cylinder into the cylinder mounting plate. See Figure 3.

WARNING: To prevent personal injury, the cylinder must be fully threaded into the cylinder mounting plate.

9. Install the cylinder mounting plate onto the end of the threaded rods. Adjust the clamping nuts as needed to ﬁt the threaded rods through the holes in the cylinder mounting plate. Assemble the hex nuts on the threaded rods. Tighten the hex nuts on both ends of the threaded rods.

10. Hold the D-pin adapter over the pivot bushing until contact is made with the adapter pin.

11. Insert the adapter pin into the head of the cylinder.

12. Prepare the hydraulic pump for use by following the instructions provided with the pump regarding hookup, venting, priming, and operation.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

13. Connect the hydraulic hose from the hydraulic pump to the cylinder.

14. Operate the pump to extend the cylinder piston and apply pressure to push the pivot bushing out of the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being extracted. It is especially important to not stand in the direction of the hydraulic force.

3

HENDRICKSON COMFORT AIR® – Pivot Bushing Installation

Figure 4

P-80

Adapter Pin

Bushing Lubricant

Pivot Bushing Installation

1. Clean and thoroughly lubricate the entire surface of the inside diameter of the beam and the outer diameter of the bushing. See Figure 4.

2. Insert the adapter pin into the head of the cylinder.

3. Place the pivot bushing on the end of the adapter pin as shown in Figure 4.

4. Operate the pump to extend the cylinder piston and apply enough pressure to hold the tool and components. Check the alignment of the pivot bushing.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

5. Operate the pump to apply pressure to install the pivot bushing completely into the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being installed. It is especially important to not stand in the direction of the hydraulic force.

4

HENDRICKSON PRIMAAX® EX – D-Pin Removal

PRIMAAX® EX

D-Pin

(52K or 46K)

Remove

Install

D-Pin Removal

1. Mark the beam to show the alignment of the existing D-pin. Install the alignment tool over the D-pin, and place the clamping plate over the alignment tool. See Figure 5.

2. Assemble the clamping nuts to the threaded rods.

575164 Saddle

4 4 4

Threaded Rod

Clamping Nut

575163

Adapter

4 4 4

576421

D-Pin

Adapter

Mark the

alignment of

the D-pin.

575165

Bushing

Support

575167

Alignment

Tool

Head Plate

Hex

Nut

3. Insert a threaded rod through the upper holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

4. Insert a threaded rod through the lower holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

5. Tighten the clamping nuts to the clamping plate. See Figure 6.

6. Remove the alignment tool.

Alignment

Tool

Figure 5

Clamping

Plate

Illustration showing the

assembly after steps 1 – 5.

Remove the

Alignment Tool.

Figure 6

5

Hex Nut

Cylinder

HENDRICKSON PRIMAAX® EX – D-Pin Removal

Cylinder

Mounting Plate

D-Pin

Adapter

Adapter Pin

Figure 7

D-Pin Removal contd.

7. Thread the cylinder into the cylinder mounting plate. See Figure 7.

WARNING: To prevent personal injury, the cylinder must be fully threaded into the cylinder mounting plate.

8. Install the cylinder mounting plate onto the end of the threaded rods. Adjust the clamping nuts as needed to ﬁt the threaded rods through the holes in the cylinder mounting plate. Assemble the hex nuts on the threaded rods. Tighten the hex nuts on both ends of the threaded rods.

9. Place the D-pin adapter over the D-pin.

10. Insert the adapter pin into the head of the cylinder.

11. Prepare the hydraulic pump for use by following the instructions provided with the pump regarding hookup, venting, priming, and operation.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

12. Connect the hydraulic hose from the hydraulic pump to the cylinder.

13. Operate the pump to extend the cylinder piston and apply pressure to push the D-pin out of the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the D-pin is being extracted. It is especially important to not stand in the direction of the hydraulic force.

6

HENDRICKSON PRIMAAX® EX – D-Pin Installation

Align D-pin with

marks made

during removal.

D-pin

Adapter

Saddle

Lubricant with

chassis grease

(NLGI #2)

Figure 8

D-Pin Installation

1. Clean and thoroughly lubricate the entire surface of the inside diameter of the beam and outer bushing. See Figure 8.

2. Insert the saddle into the head of the cylinder.

3. Assemble the new D-pin and the D-pin adapter as shown. Align the line in the D-pin adapter with the alignment marks made during the removal procedure.

4. Operate the pump to extend the cylinder piston and apply enough pressure to hold the tool and components. Check the alignment of the D-pin. The centerline of the D-pin must be aligned with the centerline of the inside diameter of the beam.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

5. Operate the pump to apply pressure to install the D-pin completely into the beam. Conﬁrm the D-pin is centered in the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the D-pin is being installed. It is especially important to not stand in the direction of the hydraulic force.

7

HENDRICKSON PRIMAAX® EX – Pivot Bushing Removal

HENDRICKSON

PRIMAAX® EX

Pivot

Bushing

Pivot Bushing Removal

1. Insert the adapter pin through the alignment tool and into the pivot bushing hole as shown in Figure 9.

2. Insert the bushing support over the pivot bushing.

Remove

Install

575164 Saddle

Threaded Rod

575163

Adapter

4 4 4 4

4 4 4

Adapter Pin

576421

D-Pin

Adapter

Alignment

575165

Bushing

Support

Bushing

Support

Tool

575167

Alignment

Tool

Head Plate

Hex

Nut

3. Assemble the clamping nuts to the threaded rods.

4. Insert a threaded rod through the upper holes in the clamping plate and the head plate while positioning the head plate over the bushing support. Install a hex nut on the threaded rod, but do not tighten at this time.

5. Insert a threaded rod through the lower holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

Clamping Nut

Remove the

Alignment Tool

and Adapter Pin.

Figure 9

Clamping

Plate

Illustration showing the

assembly after steps 1 – 6.

Figure 10

6. Tighten the clamping nuts to the clamping plate. See Figure 10.

7. Remove the alignment tool and adapter pin.

8

HENDRICKSON PRIMAAX® EX – Pivot Bushing Removal

Cylinder

Mounting Plate

Hex Nut

Cylinder

D-Pin

Adapter

Figure 11

Adapter Pin

Pivot Bushing Removal contd.

8. Thread the cylinder into the cylinder mounting plate. See Figure 11.

WARNING: To prevent personal injury, the cylinder must be fully threaded into the cylinder mounting plate.

9. Install the cylinder mounting plate onto the end of the threaded rods. Adjust the clamping nuts as needed to ﬁt the threaded rods through the holes in the cylinder mounting plate. Assemble the hex nuts on the threaded rods. Tighten the hex nuts on both ends of the threaded rods.

10. Hold the D-pin adapter over the pivot bushing until contact is made with the adapter pin.

11. Insert the adapter pin into the head of the cylinder.

12. Prepare the hydraulic pump for use by following the instructions provided with the pump regarding hookup, venting, priming, and operation.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

13. Connect the hydraulic hose from the hydraulic pump to the cylinder.

14. Operate the pump to extend the cylinder piston and apply pressure to push the pivot bushing out of the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being extracted. It is especially important to not stand in the direction of the hydraulic force.

9

HENDRICKSON PRIMAAX® EX – Pivot Bushing Installation

Figure 12

P-80

Adapter Pin

Bushing Lubricant

Pivot Bushing Installation

1. Clean and thoroughly lubricate the entire surface of the inside diameter of the beam and the outer diameter of the bushing. See Figure 12.

2. Insert the adapter pin into the head of the cylinder.

3. Place the pivot bushing on the end of the adapter pin as shown.

4. Operate the pump to extend the cylinder piston and apply enough pressure to hold the tool and components. Check the alignment of the pivot bushing.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

5. Operate the pump to apply pressure to install the pivot bushing completely into the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being installed. It is especially important to not stand in the direction of the hydraulic force.

10

FCCC V-RIDE™– D-Pin Removal

FCCC V-Ride™

D-Pin

(52K or 46K)

D-Pin Removal

1. Mark the beam to show the alignment of the existing D-pin. Install the alignment tool over the D-pin, and place the clamping plate over the alignment tool. See Figure 13.

2. Insert the bushing support into the head plate.

Remove

Install

575164 Saddle

4 4 4 4

Threaded Rod

Clamping Nut

575163

Adapter

4 4 4 4

576421

D-Pin

Adapter

Mark the

alignment of

the D-pin.

575165

Bushing

Support

Bushing

Support

575167

Alignment

Tool

Head Plate

Hex

Nut

3. Assemble the clamping nuts to the threaded rods.

4. Insert a threaded rod through the upper holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

5. Insert a threaded rod through the lower holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

6. Tighten the clamping nuts to the clamping plate. See Figure 14.

Remove the

Alignment Tool.

Clamping

Plate

Alignment

Tool

Figure 13

Illustration showing the

assembly after steps 1 – 6.

Figure 14

7. Remove the alignment tool.

11

Hex Nut

Cylinder

FCCC V-RIDE™– D-Pin Removal

Cylinder

Mounting Plate

D-Pin

Adapter

Adapter Pin

Figure 15

D-Pin Removal contd.

8. Thread the cylinder into the cylinder mounting plate. See Figure 15.

WARNING: To prevent personal injury, the cylinder must be fully threaded into the cylinder mounting plate.

9. Install the cylinder mounting plate onto the end of the threaded rods. Adjust the clamping nuts as needed to ﬁt the threaded rods through the holes in the cylinder mounting plate. Assemble the hex nuts on the threaded rods. Tighten the hex nuts on both ends of the threaded rods.

10. Place the D-pin adapter over the D-pin.

11. Inser t the adapter pin into the head of the cylinder.

12. Prepare the hydraulic pump for use by following the instructions provided with the pump regarding hookup, venting, priming, and operation.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

13. Connect the hydraulic hose from the hydraulic pump to the cylinder.

14. Operate the pump to extend the cylinder piston and apply pressure to push the D-pin out of the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the D-pin is being extracted. It is especially important to not stand in the direction of the hydraulic force.

12

FCCC V-RIDE™– D-Pin Installation

Align D-pin with

marks made

during removal.

D-pin

Adapter

Saddle

Lubricant with

chassis grease

(NLGI #2)

Figure 16

D-Pin Installation

1. Clean and thoroughly lubricate the entire surface of the inside diameter of the beam and outer bushing. See Figure 16.

2. Insert the saddle into the head of the cylinder.

3. Assemble the new D-pin and the D-pin adapter as shown. Align the line in the D-pin adapter with the alignment marks made during the removal procedure.

4. Operate the pump to extend the cylinder piston and apply enough pressure to hold the tool and components. Check the alignment of the D-pin. The centerline of the D-pin must be aligned with the centerline of the inside diameter of the beam.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

5. Operate the pump to apply pressure to install the D-Pin completely into the beam. Conﬁrm the D-pin is centered in the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the D-pin is being installed. It is especially important to not stand in the direction of the hydraulic force.

13

FCCC V-RIDE™– Pivot Bushing Removal

FCCC V-Ride™

Pivot

Bushing

Pivot Bushing Removal

1. Insert the adapter pin through the alignment tool and into the pivot bushing hole as shown in Figure 17.

2. Assemble the clamping

nuts to the threaded rods.

Remove

Install

Threaded

Rod

575164 Saddle

575163

Adapter

4 4 4

4 4

Adapter Pin

576421

D-Pin

Adapter

Alignment

Tool

575165

Bushing

Support

Head Plate

575167

Alignment

Tool

Hex

Nut

3. Insert a threaded rod through the upper holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

4. Insert a threaded rod through the lower holes in the clamping plate and the head plate. Install a hex nut on the threaded rod, but do not tighten at this time.

5. Tighten the clamping nuts to the clamping plate. See Figure 18.

6. Remove the alignment tool and adapter pin.

Clamping

Nut

Remove the

Alignment Tool

and Adapter Pin.

Clamping

Plate

Figure 17

Illustration showing the

assembly after steps 1 – 5.

14

Figure 18

FCCC V-RIDE™– Pivot Bushing Removal

Cylinder

Mounting Plate

Hex Nut

Cylinder

D-Pin

Adapter

Figure 19

Adapter Pin

Pivot Bushing Removal contd.

7. Thread the cylinder into the cylinder mounting plate. See Figure 19.

WARNING: To prevent personal injury, the cylinder must be fully threaded into the cylinder mounting plate.

8. Install the cylinder mounting plate onto the end of the threaded rods. Adjust the clamping nuts as needed to ﬁt the threaded rods through the holes in the cylinder mounting plate. Assemble the hex nuts on the threaded rods. Tighten the hex nuts on both ends of the threaded rods.

9. Hold the D-pin adapter over the pivot bushing until contact is made with the adapter pin.

10. Insert the adapter pin into the head of the cylinder.

11. Prepare the hydraulic pump for use by following the instructions provided with the pump regarding hookup, venting, priming, and operation.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

12. Connect the hydraulic hose from the hydraulic pump to the cylinder.

13. Operate the pump to extend the cylinder piston and apply pressure to push the pivot bushing out of the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being extracted. It is especially important to not stand in the direction of the hydraulic force.

15

FCCC V-RIDE™– Pivot Bushing Installation

Figure 20

P-80

Bushing Lubricant

Adapter Pin

Pivot Bushing Installation

1. Clean and thoroughly lubricate the entire surface of the inside diameter of the beam and outer diameter of the bushing. See Figure 20.

2. Insert the adapter pin into the head of the cylinder.

3. Place the pivot bushing on the end of the adapter pin as shown.

4. Operate the pump to extend the cylinder piston and apply enough pressure to hold the tool and components. Check the alignment of the pivot bushing.

WARNING: To prevent personal injury, pump capacity must not exceed 10,000 psi.

5. Operate the pump to apply pressure to install the pivot bushing completely into the beam.

WARNING: To prevent personal injury from possible breakage under pressure, do not stand in the vicinity of the tool while the pivot bushing is being installed. It is especially important to not stand in the direction of the hydraulic force.

16

Parts List

6

4

3

2

1

7

5

8

9

Item No. Part No. Qty. Description

1

2

3

4

5

6

7

8

9

10

11

12

576924

575170

575173

575169

575171

575172

4106A

575164

576421

575163

575167

575165

575166

104031

36886

2510A

9798

1 Hex Nut Kit (contains four nuts)

2 Threaded Rod

1 Cylinder Mounting Plate

2 Clamping Nut

1 Clamping Plate

1 Head Plate

1 Hydraulic Cylinder (25 Ton)

1 Saddle

1 D-Pin Adapter

1 Adapter Pin

1 Alignment Tool

1 Bushing Support

1 Warning Decal (not shown)

1 Warranty / Authorized Service Center List (not shown)

1 Hose Assembly (4247 only; not shown)

1 Air / Hydraulic Pump (4247 only; not shown)

1 Hose Half Coupler (4247 only; not shown)

10

11

12

17

Adapter Kits

The chart below outlines the Hendrickson Suspension Tool packages and Adapter Kits available for speciﬁc Hendrickson applications. If you currently own one tool package, consider purchasing adapter kits for other speciﬁc applications.

Hendrickson Adapter Kits available

Hendrickson

Tool

Package

Part No.

4246

4247

4261

4274

4275

Tool

Packages

include

items

marked

w/ 4

No. 2510A

Air/Hyd. Pump

(w/ hose &

coupler)

4 4 4

No. 4250

(Volvo, Navistar,

No. 4263

and Paccar)

Bare Tool

4 4

No. 4254

(Comfort Air,

Primaxx EX, and

FCCC V-Ride)

No. 4255

(AIRTEK NXT

[rear bushing

only])

18

Inspection and Maintenance

CAUTION: To prevent personal injury,

Only qualiﬁed personnel shall perform inspections to this Hendrickson Rear Suspension

•

Bushing Tool.

Before each use, an approved inspector must inspect the suspension bushing tool for bends,

•

cracks, dents, elongated holes, or missing hardware. If damage is found, discontinue use.

Use only those repair parts called out in the parts list in this document. Items found in the parts

•

list have been carefully tested and selected by OTC.

Maintenance

To prevent contamination from entering the hydraulic system and damaging the cylinder, keep the cylinder clean. When the cylinder is not in use, keep the piston rod fully retracted and stored upside down. Use protective covers on disconnected quick couplers.

Disposal

At the end of its useful life, dispose of the suspension bushing tool according to federal, state, and local regulations.

Order replacement parts

at OTCparts.com

This document contains product parts lists and information regarding operation and maintenance. Items listed in the parts list have been carefully tested and selected by OTC. Therefore, use only OTC replacement parts.

Product questions may be directed to the OTC Technical Service Department at (800) 533-6127.

19

655 Eisenhower Drive Owatonna, MN 55060 USA Phone: (507) 455-7000 Tech. Serv.: (800) 533-6127 Fax: (800) 955-8329 Order Entry: (800) 533-6127 Fax: (800) 283-8665 International Sales: (507) 455-7223 Fax: (507) 455-7063