W&C SL20K User manual

W&C214
REV
03
.
01
.201
7
1. Introduction ____________________________1
1.1InstallerResponsibility_______________ 1
2. BeforeYou Begin________________________1
2.1SafetyExplanations _________________ 2
2.2Warning__________________________ 2
2.3Identifying YourModel_______________ 2
3. RideHeight_____________________________3
3.1CalculatingRide Height______________ 3
4. Installation_____________________________4
4.1MountingtheSuspension_____________ 4
4.2AdjustingMaximumTurnAngle________ 8
4.3AdjustingWheel Toe-in______________ 9
5. TorqueRequirements___________________10
5.1Torque Guidelines _________________ 11
6. AirPressurevs.LoadGuide______________13
SL2065 Series PressureChart___________ 13
7. PartsList_____________________________14
8. Service Kits___________________________19
9. Quick-changeRideHeight_______________21
10. Preventive MaintenanceError! Bookmarknotdefined.
TABLEOF CONTENTS

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
1
1.Introduction
Thispublicationisto acquaint and assistyouin
installing and operating the Watson &Chalin
AuxiliarySteerableLiftableAirRide Suspension
ProductLine and isintended foruseonlywith
thisProductLine.
Thismanualincludesinstallationandoperating
information on Watson &Chalin modelnumbers:
SL-2065
Watson &Chalinreservesthe right to changeits
productsormanualsat anytime. ContactWatson
&Chalinat 1.800.445.0736 forinformation on
recent changesto products.
Defectivecomponentsshouldbe returnedto
Watson &Chalinwithapre-arrangedReturned
GoodsAuthorization (RGA)numberthrough the
warrantydepartment. If the defectisin
compliancewithwarrantyconditions,the
defective component maythen be replaced.
Ifthe partisdamagedinshipment, please
contactthe freight companytofileaclaim.The
freight companyisresponsible foranydamage to
componentsduring shipment.
IMPORTANT
The entiremanualmustberead and understood
beforeproceeding with installation orserviceof
anycomponents.
Thismanualshouldbe used inconjunction with
corresponding drawingsthat comewith Watson
&Chalin suspensionsupondelivery.
The vehiclemanufacturermustapproveany
changestothevehicleframebeforethe changes
aredone.Cuttingoraltering the vehicle’sframe
isnormallynotpermitted bythemanufacturer
and affectsthe manufacturer’swarranty
coverage.
1.1InstallerResponsibility
The installerofthe suspension systemmust:
•Ensurethatthevehiclefunctionsproperly
with the increased weightofan additional
axle.
•Determine thecorrectlocationofthe
suspensionto provide the propervehicleload
distribution astonotexceed therated
capacityofthecomponentsinvolved.
•Ensuretheinstallation ofthe correctbrake
systemcomponentsto guarantee proper
braking performance. Brakeinstallation must
complywith FMVSS121 specifications.
•Ensurethat properclearanceexistsbetween
the drive shaft and the auxiliaryaxle.
•Ensuresuspensionoperateswithinrun
range.
2.BeforeYou Begin
Beforeyoubegintoinstall the Watson &Chalin
suspension system,youmust:
•Checkspecificationson suspensionsystems
to be surethat thecorrectsuspension
systemwaschosen forthevehicle.
•Verifythe vehicleframewidthiswithinthe
allowablemounting range ofthe suspension
and that thevehiclecrossmembers are
correctlypositioned.
•Markthe locationofthesuspensionside rails
and checkforinterferenceswith existing
bracketryand components.
•Checkforinterferencebetweentheaxleand
drive shaft.

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
2
•Ensuresuspensionoperateswithinthe run
range.
2.1SafetyExplanations
Watson &Chalinusesthe followingtypesof
notestowarnagainstpossiblesafetyproblems
and to giveinformation that helpsto prevent
damage to equipment.
IMPORTANT
Animportant message indicatesaprocedurethat
should befollowedexactly.
Awarningindicateshazardsorunsafepractices
that couldresultinseverepersonalinjuryor
death, ifthe procedureisnot followedexactly.
Allsafetystatementsshouldbe read carefullyto
prevent bodilyinjury,to assurethat partsare
assembled properlyand toretainthe
manufacturer’swarranty.
2.2Warning
Properaxleattachmentrequired forsafe
operation ofthe vehicle.
No alteration ofanyWatson&Chalinsuspension
componentsispermitted without proper
authorization fromqualified Watson &Chalin
personnel.
No welding ofanysuspension componentsis
permitted except when specified byWatson &
Chalin.
2.3Identifying Your Model
IMPORTANT
It isimportant that you knowwhat modelnumber
hasbeen assignedto yourassemblyincaseyou
everneed to contactWatson &Chalin.
Identification Plate
Eachsuspensionassemblyhasan identification
platelocated on theleftside railassembly.This
ison the driver’sside ofthe vehicle. The plate
includesthe modelnumber,serialnumberand
capacityinpoundsforthe assembly.Itis
important torecordthe modelandserialnumber
forfuture reference.
FIG
–
1 Identification Plate

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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3.RideHeight
RideHeight, alsoreferredto asRunHeight, is
the distancebetween thesuspensionmounting
surface, orthebottomofthe vehicleframeand
the spindlecenterofthe auxiliaryliftableaxlein
the loweredrunposition. It isoneofthemost
important dimensionstoobtainandwhenset
properly,allowsfortheoptimumamount oflift
that the axle can achieve.
IMPORTANT
Acorrectinstallation requiresthat the suspension
ride heightbewithintherangespecifiedonthe
correspondingdrawingwhen the vehicleisinits
loaded condition.
Watson &Chalinprovidesnumerousdifferent SL
seriessuspensionsystemsto accommodate
different vehicle ride heightsand capacities.
3.1Calculating RideHeight
ProperRide Height iscalculated with the
following equation:
Ground to Bottomof
Vehicle Frame (loaded)______________
StaticLoaded Tire Radius– ______________
RideHeight=_______________
** The SL2065 seriesisequipped with theW&C
quick-change ride height system. Ifit is
determined above that a ride height change is
necessaryand the resultingrun height fallswithin
a designed allowablerange, referto the Quick-
changeRide Height sectionon page21 for
detailson changing spacers.
FIG
–
2 Ride Height

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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FIG
–
3
Pusherand TagAxle Alignment
4.Installation
The following instructionsareforinstalling the
componentsofthe Watson&ChalinSLSeries
Suspensionsystems.All modelnumbers inthe
seriesareinstalled usingthe sameset of
instructions.Watson &Chalinassumesthat the
correctauxiliarysuspension and axlewere
chosen based on the individualdesign criteria.
The suspension systemsmustbe installed with
the properamount oftire-to-groundclearanceto
ensuretroublefree operation ofthe vehicle. If
thereistoomuchground clearance, the
suspensionwillnot carryitsshareofthe load,
straining theothersuspension components.
When thereistoolittleground clearanceorifthe
suspensionisoverloaded, the vehiclewill bottom
out whilegoingoverbumpsand damage can be
doneto the suspensioncomponentsorother
componentson the vehicle.
4.1Mounting theSuspension
Before mounting the suspension, you must:
•Confirmthat the propersuspensionand axle
waschosenbased onyourcompany’s
specifications.
•Ensurethechassisframehasthe proper
crossmemberreinforcement inthearea
wheretheauxiliaryaxlehanger/railis
located. SeeFigure 4.
•Ifthe vehicleframewaspredrilled for
mounting the SLseriesaxlepriorto
purchase, be sureto alignto and usethese
fastenerpositions.
•Alsorememberto removetheassociated
boltsfromthe framepriorto axlealignment
and installation.

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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NOTE
Throughouttheinstallationprocess you must
checkfrequentlyforsuspension clearance
problemswhile mounting the suspension.
FIG
–
4
Chassis CrossmemberReinforcement

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
6
Tomount the suspensionto the vehicle:
1. Placethevehicleon alevelsurface.
2. Markthe approximate locationofthe
suspensionside railassemblieson the
vehicleframe rails.
3. Checkforinterferencewith anyexisting
bracketsormounting bolts.
4. Locate the auxiliaryaxle mountingposition.
5. Fromthe centerlineofthe axleat thewheel
center,markthe location ofthisaxle
measurement on theoutside ofthevehicle
frame rail.
6. Raisethebackend ofthe frameusing either
alift, jack ordrivingthe rearaxlesand tires
onto a lift.
7. Raisethe suspensioninto position using the
marked axle, front hangerrail andupperbag
plate centerlineaslocators.
NOTE
If,whileraisingthe SLseriessuspension into
place,thehangers getstuckon the frame
becausetheyaretoonarrow,loosen the boltson
one sideofthe crossmember.Thiswill allowthe
hangers to separateenough tomoveinto
position. Ifyou haveawelded crossmemberyou
willnot be ableto loosen inthisway.
8. Using clamps, clamp the suspension railto
the vehicleframe rail.
IMPORTANT
Boththesideand bottommountingsurfaces
mustsitflushwith theside and bottomofthe
vehicleframerailsorspacers,orthe suspension
warrantyisinvalid.See Figure 6.
FIG
–
5
Suspension
M
ounting
Position

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
7
9. Markthe locationofthe mounting holeson
the outside ofboth suspension frame rails.
10.Inspectvehicleframerailsforanyitemsthat
maycause drilling obstructions.
Welding, drillingorboltingthroughthe bottom
flange ofthe suspension frameorvehiclerails
voidsthe manufacturer’swarranty.
NOTE
3/4”SAEGrade8UNFfasteners requiredto
attachtheSL2065suspensiontothevehicle
frame.
11.Drilltwo 13/16”holesthrougheach
suspension railand vehicleframe rail.
12.Fasten eachsuspensionside rail to the
vehicleframeusing the appropriate
size/gradefastenerspecified above, flat
washerand locknut. Useat least2boltsper
side.
13.Drill remaining mountingholespersiderail.
SeeFigure7orthesuppliedsuspension
drawing forrecommended fastenerquantities
and locations.
14.Installthe remainingbolts,washers and lock
nutsandtighten capscrewsto propertorque.
See“Torque Requirements” on page13 for
details.
15.Drillaminimumoftwo13/16”diameterholes
throughtheupperairspring mounting
bracketsand chassisframe.
16.Fasten eachbagplateassemblywithtwo¾”
SAEgrade 8UNFfine thread cap screws,
flat washers and locknutsasseen infigure
7.
NOTE
Hangers mustbe parallelto oneanotherto
ensure properoperation.
FIG
–
6
Frame
Alignment

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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17.Attachcrossmemberto the suspension front
hangers with suppliedfasteners and tighten
to specified torque values.
18.Removethe clampfromthe vehicleframe
rails.
4.2Adjusting Maximum Turn Angle
Thissection isused to check and adjust, if
necessary,themaximumturnangleofyour
SL2065 suspension system inordertoobtain
properclearance.
Toadjustthe maximum TurnAngle:
1. Measurethe current Turn Angle.
2. The maximumturnangleforSL2065Series
modelisnormallyset at the maximum25º.
Someapplicationsmayrequireless turn
angle.
3. Ifthe turnangleneedstobeadjusted,adjust
the stopboltuntil the correctangleis
obtained on both sides.
4. To obtainthemaximumTurn Angle:
a. Loosen the stop boltjamnut asseenin
Figure8.
b. Adjustthe turnanglebyadjustingthe
stop boltinorout.
c.Tighten the jamnut to 50-75 lbs./ft.
Do not turnthestopboltsomuchthat the bolt
end protrudespastthe brakespiderasthiscan
cause damage toothercomponents.
FIG– 7 RecommendedFastening Method
FIG– 8 Stop BoltLocation

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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4.3Adjusting WheelToe-in
Toe-inisthe relationshipofthe distancebetween
the front andrearofthe tiresorthe amount at
whichthefront wheelspoint inward. Toe-out is
the amount at whichthetirespointoutward.
When the front distanceis less than the rear
distance,thewheelsareina“toe-in”condition.
Mosttireweariscaused byincorrecttoe settings.
Toe-inmustbe verified andadjusted,ifrequired,
during suspensioninstallation.
To adjust wheelToe-in:
1. Placethevehicleon alevelsurface.
2. Lift the axleuntil tiresarefree tospin.
3. Usepaint orchalkto markthe horizontal
centeroftiresaroundthecomplete outer
surface ofthe tire.
4. Placethe pointers ofatrammelbaron the
marks of eachtireand rotatethe tiresmaking
sure a straight line hasbeen marked.
5. Measureandrecordthedistanceattheback
ofthe tires.
6. Measureand recordthedistanceat the front
ofthe tires.
7. Usethe following calculationto determine the
Toe-in measurement.
Distancebetweenbacktires(R)__________
Distancebetweenfront tires(F) –__________
Toe-in must be “0.09”+or– “0.03”.=________
NOTE
ApositiveresultisconsideredToe-inanda
negative resultisconsidered Toe-out.
8. Ifthe Toe-inmeasurement isnot at the
specified distance:
•Loosen clampboltsand nutsat eachend of
the tie rod.
•Turntierod tube with apipewrenchto adjust
wheelToe-in.
•Tighten clamp boltsto the propertorque.
9. Repeat step 1through step 8until correct
Toe-in isobtained.
FIG
–
9 Toe
-
in

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5.TorqueRequirements
Torque specificationslisted inthe followingtables
areapplied to nuts,butnot bolts.Alltorque
requirementsareforlubricated threadsonly.A
lubricatedthreadisdefined asabolted
connection thathassomeformof friction modifier
orlubricantappliedtothethreadsurfaces,which
providesa lowertorque requirement.
FIG– 10 Knuckle Component Torque Illustration

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Table 2
5.1TorqueGuidelines
The followingtableshowsthe propertorque
requirementsforthe capscrewsand nuts
described.Eachtypeofcap screwand nut is
showninthe followingTablesaccording tothe
itemnumber.
Torque Requirement Procedures
Allfasteners shouldbe re-torqued according to
the following schedule.
•After30 days
•Every6 monthsthereafter
NOTE
Torque valuesinTable2do not applytoair
springsorlowergrade fasteners.
Table 2, Capscrew/bolt(Grade 8UNF) Torque
Requirements **
**Torque valuesshownapplyonlyto W&C supplied fasteners. Ifotherfasteners are used, follow torque
specificationslisted invehicle manufacturer’sservicemanual.
Item # Description Size TorqueRange(lb.-ft.)
25 Backbone/Upper KingpinAssemblyNut7/8”-14 425
26 Tie-Rod End toTie-Rod ArmCastleNut7/8”-14 160-300
28 Stabilizer Shock Nut3/4”-16 200-250
32 (IntegratedBrake) Anchor PinNut5/8”-18 175
32 (Bolt-on Brake) Attachment Nut3/4”-16 200 –225
DrawKeyNut7/16”-20 30-45
GreaseFitting1/8” NPT10
Cross Tube ClampNut5/8”-11 60-80
Stop ScrewLock/JamNut1/2”-13 50-75
Capscrew/boltSize 3/8” 1/2” 5/8” 3/4” 3/4" (StabilizerShock Stud) 7/8” 1” 11/8”
Torque minimumft./lbs.25 50 150 300 200 500 700 900
Torque maximumft./lbs. 35 75 200 350 250 550 800 1000
Table 1

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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FIG– 11 U-BoltTorque Pattern
Table 3
Table 4
Table 5
U-boltTorque Instructions
Tore-torque U-bolts:See Table 3
1. Partiallytighten bolts#1 and #2 according tofigure11.
2. Partiallytighten bolts#3 and #4.
Using the same sequence, torque to the propertorque asspecified below.
U-Bolt(Non-PlatedCleanLubricatedThread) Torque Requirements.
Airspring Torque Requirements.
Airspring AirFitting Torque Requirements.
UNFGrade8Size 3/8” 1/2” 5/8” 3/4” 7/8” 1” 11/8”
UBoltminimumft./lbs.15 40 120 200 400 650 800
UBolt maximumft./lbs. 20 60 150 250 450 750 900
Size Description MaxTorqueRequirement(ft./lbs.)
3/8” UNC Blind Nuts50
1/2” UNC Boltor Stud25
3/4” UNC Stud55
3/4” UNFCombo Stud50
Size MaxTorqueRequirement(ft./lbs.)
1/4” NPTF 50
1/2” NPTF 25
3/4” NPTF 55

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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Table 6
6.Air Pressurevs. LoadGuide
The following tablesdescribe the properair
pressuresettingsandrun heightsforeachSL
seriesmodelnumber.
SL2065 Series PressureChart
6000 8000 1000012000140001600017000180001900020000Outputat
Ground
Model number RideHeight PSIrequired toachieveOutput at Ground
SL2065-10 818273544526165707478
9.25 19283746556569747883
10.5 20304049596873788388
SL2065-11 918273544526165707478
10.2519283746556569747883
11.5 20304049596873788388
SL2065-12 1018273544526165707478
11.2519283746556569747883
12.5 20304049596873788388
SL2065-13 1118273544526165707478
12.2519283746556569747883
13.5 20304049596873788388
Somecapacitiesshownmaynotbe best suitedforthesuspensionbasedontoo muchbrakeforcefortheappliedload.Therefore,brakingcapacitymay
havetobedownsizedtoaccommodate.
Pressure requirements are approximationsand will need tobe calibrated on aweigh scalecapableofhandlingtheOutputatGroundforcesinthe above
chart.
Weight oftheaxle,hubsanddrums based on 385/65R22.5tires, steelwheels, andcast hubsand drums ------------------------------1800
Indicatestarget Ride Height for this tabulation

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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7.PartsList
The following section showsthe explodedviewofthe SL2065 serieslift axle. Thisviewand
corresponding partslistinthe following tableisintended tohelpyouidentifypartsand partnumbers that
mayneed to be replaced.
FIG- 12 - SL2065 Exploded View

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
15
ITEMNO. QTY PARTNO. DESCRIPTION
11CHART1HANGER ASSEMBLYL.H.
21CHART1HANGER ASSEMBLYR.H.
31930274-10 ARM ASSYLH
41930274-20 ARM ASSYRH
5217832 TORQUEROD
61160131AXLEASSEMBLY
71CHART2CROSSMEMBER
81HPCM16093CROSSMEMBERHARDWAREPACK
91CHARTUPPERBAGPLATELH
101CHARTUPPERBAGPLATERH
112AS0222 AIR SPRINGLOAD
121CHART3LOWER BAGPLATELH
131CHART3LOWER BAGPLATERH
141HPLD2055 AIRBAGHARDWAREPACK(LOAD)
15250193-01LIFTBAGPLATE
162AS0058CAIR SPRINGLIFT(6897)
171HPLT16085 LIFTBAGHARDWAREPACK
181CHART4LIFTBAGPLUMBINGKIT/HARDWARE
191CHART2SL2055 COMMONPVTHDWE
201HPPT16094PIVOTCONNECTION PACK
211 011707-1BACKBONELH 20K(INT. BRAKE)
012137-1BACKBONELH 20K(BOLT-ON BRAKE)
221 011707-2BACKBONERH 20K(INT.BRAKE)
012137-2BACKBONERH 20K(BOLT-ON BRAKE)
231 009957UPPERKINGPIN ASSYLH (INT. BRAKE)
011918-1UPPERKINGPIN ASSYLH (BOLT-ON BRAKE)
241 009957UPPERKINGPIN ASSYRH (INT. BRAKE)
011918-2UPPERKINGPIN ASSYLH (BOLT-ON BRAKE)
25 1HPKN20KFKNUCKLEHARDWAREKIT(INT. BRAKE)
2T1822SGXTHRUSTBEARING(BOLT-ON BRAKE)
261990188-06 TIEROD ASSY
27211418 SHOCKSTEERINGSTABILIZER
281HPSS2065SL2065 STEERSTABILIZER HARDWARE
291006703-1L S-CAM LH (SHOWN)(INT. BRAKEONLY)
301006703-1RS-CAM RH (INT. BRAKEONLY)
314010113BRAKESHOE(INT. BRAKEONLY)

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
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321 HPBH20KFBRAKEHARDWAREKIT(INT. BRAKE)
HPBH20KF-01BRAKEHARDWAREKIT(BOLT-ON BRAKE)
332REF. ONLYHUBASSEMBLY
342REF. ONLYBRAKEDRUM
352REF. ONLYSEAL
362REF. ONLYINNERBEARING
372REF. ONLYOUTER BEARING
382REF. ONLYSPINDLENUT
392REF. ONLYHUBCAP
402REF. ONLYBRAKECHAMBER
412REF. ONLYSLACKADJUSTER
42210050 TRAILINGARM BUSHING,FRONT
43211938-91TRAILINGARM BUSHING,REAR
FIG- 13 - SL2065 Hanger ConfigurationsView

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CHART1- SL2065 Hanger ConfigurationsChart

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
18
CHART2- SL2065 FrameWidthChart
CHART3- SL2065 Side Rail Height Chart
CHART4- SL2065 Run Height Chart

SL20KSelf-Steering Axleand Suspension SystemInstallation Manual
19
8.Service Kits
TorqueRodKit
SRK2055-1 – Torque RodKit.Containspartsfor2 torque rods.
QTY PARTNO. DESCRIPTION
8
17010
WASHER FLAT .88X1.5
4
11457
NUT LOCK.88
-
14 GRC
4
17238
-
5
CAPSCREW.87X 5.00
2
17832
TORQUEROD
20KTT
HOLLOW BALL P00
-
0230
SRK2055-1-01 – Torque RodKit.Containspartsfor1 torque rod.
QTY PARTNO. DESCRIPTION
4
17010
WASHER FLAT .88X1.5
2
11457
NUT LOCK.88
-
14 GRC
2
17238
-
5
CAPSCREW.87X 5.00
1
17832
TORQUEROD20KTT
HOLLOW BALL
P00
-
0230
Bushing Kit
SRK2055-2 – Trailing ArmBushing Kit.Containspartsfor2 trailing arms.
QTY PARTNO. DESCRIPTION
2
10050
TRAILINGARM BUSHING, FRONT
2
11938
-
91
TRAILINGARM BUSHING, REAR
4
11457
NUT LOCK.88
-
14 GRC
8
17010
WASHER FLAT
.88X1.5
2
17238
-
8
CAPSCREW.87X 8.00UNF
2
17238
-
11.5
CAPSCREW.87X 11.50 UNF
2
19721
-
05
DELRINLINER 1.13X5.00"
12
11222
-
02
WASHER FLAT .91X4.25X.25