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ReaR axle & SuSpenSiOn - Central States Bus Sales, Inc.

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3. SERVICE MANUAL COMFORT AIR H 3 Tighten locknuts to A 20 30 foot pounds torque 4 install brass fitting in air spring using Teflon thread seal 5 Connect air line to air spring 6 Remove jack stands and lower frame of vehicle 7 Air up system CROSS CHANNEL DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the locknuts and washers that connect air springs to the cross channel and push air springs out of cross channel 5 Remove the 4 bolts washers and locknuts that connect the lower linkage mounting bracket to the cross channel See Parts Lists in Section 4 6 Remove the 34 bolts washers and locknuts that connect the cross channel fo the main support member assemblies 7 Remove cross channel ASSEMBLY 1 Install the cross channel to the lower shock absorber brackets and main support mem ber assemblies by attaching the 34 bolts washers and locknuts Tighten to A 260 320 foot pounds torque 2 Install air springs in cross channel by inserting studs into appropriate holes and attach washers and locknuts Tighten locknuts to 3 20 30 foot pounds torque 3 Install the lower linkage mounting bracket to the cross channel by attaching the 1 4
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6. O Overview Rear Suspension This chapter includes routine maintenance and a procedure for removal of the axle and suspension from the bus chassis Manufacturer s documentation is provided in the appendixes and on the TechReference CD for more involved servicing of the axle and suspenion components All Americans are equipped with one of three rear suspension systems Hendrickson Softek The Softek rear suspension is a 13 leaf AAFE or 14 leaf AARE slipper spring configuration and is standard equipment on both Front Engine and Rear Engine All American Hendrickson Comfort Air The Comfort Air rear suspension is a trailing arm con figuration with 2 heavy duty rolling lobe air springs mounted rearward of axle and steel springs forward of the axle The system features a quick align dog tracking ad justment A transverse track rod controls lateral motion Vertical motion is controlled by two 138 bore Sachs shock absorbers A single height control valve maintains sus pension height at varying loads Ridewell Model 227 The Ridewell 227 rear suspension is a 4 bag air spring sus pension incorporating a parallelogram linkage and is optional on Rear Engine American only Vertical motion is controlled by adjustable heavy duty Koni shock absorbers Two leveling valves permit leveling side to side and front to rear Axle dog tracking is adjustable via eccentric torque arm bolts Forward Engine Rear Axle Meritor
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8. 1 Center axle in chassis as follows 1 1 With chassis at normal ride height measure from outside face of frame rail web to drive axle brake mounting flange edge of brake drum or edge of tire w new tires only Do for both sides If measurements are within 1 8 skip to step 4 0 BLUE BIRD REAR AXLE amp SUSPENSION 1 2 Loosen track rod pinch bolts and with pipe wrench rotate track rod shaft item 18 to move frame laterally relative to axle 13 Repeat steps 1 and 2 until axle has been centered within 1 8 14 Retighten pinch bolts to 150 ft lbs 2 Axle Dog Track Alignment 2 1 Using beeline or other suitable equipment make standard check for drive axle dog tracking If laser mark is within 1 4 of center no further 28 1 drive axle alignment is required Skip to step 3 2 2 If laser mark is greater than 1 4 from center loosen nuts item 28 Rotate eccentric bolts item 27 on appropriate side to center laser mark Rotate both upper and lower eccentric bolts equally Rotating eccentric bolts on both sides of chassis in opposite directions may be required to center laser mark 2 3 Torque drive axle eccentric bolt nuts item 28 to 1000 ft Ibs 24 Add anti turn washers item 26 over head of eccentric bolt item 27 and weld to receiver ring Adjusting of Koni Shocks 1 Remove the shock absorber from the vehicle Place the lower eye attach ment In a vise Fully collapse shock absorber while tur
9. Bonded rubber bushings nat E 1 4 FN 1130003 GRE woxed 7 bolt 7 forged n 05 2 4 7 16 bush HHCS 1 1 2 amp NC 7 long ME d 11605198903 Bearing washer shim t 90030928000 Anitan washer 2 APPENDIX
10. I sums 2 525 575 ff Ibs a 7 40 50 in lbs 20 30 ft Ibs BN Sy ae 450 70 ft Ibs 7 3 160 180 ff Ibs 7 8 Locknut OR 34 Locknut Tightening Torque Tightening Torque 400 450 ff Ibs 285 305 ff Ibs 30 17730 246 BLUE BIRD APPENDIX REAR AXLE amp SUSPENSION APPENDIXES H COMFORT AIR COMFORT AIR HENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS 1 U Bolt high locknut 19 000 to 23 000 Ib capacity 8 7 8 400 450 15 000 Ib capacity 8 3 4 285 305 Frame Fasteners Furnished amp Installed by Truck Manufacturer QUIK ALIGN Locknut 525 575 DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATE WARNING FASTENERS TO MAINTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY 3 Shock Absorber Upper Shock Mount Locknut 2 1 2 50 70 4 Shock Absorber Lower Shock Mount Locknut 2 3 4 160 180 5 Cross Channel to Main Support Member Locknut 4 3 4 260 320 6 Air Spring to Cross Channel Locknut 2 1 2 20 30 7 Extension Rod Bracket fo Cross Channel Locknut 2 1 4 40 50 in Ibs 8 Height Control Valve Arm to Extension Rod Stud Locknut 2 5 16 80 90 in Ibs 9 Height Control Valve Studs to Frame Locknut 2 1 4 40 50 in Ibs Adj Valve Arm Joint Stud to Bracket
11. 1 3 e GERD 5211 NJ INI WOLNO SONLLLLJ INS 01 0310907 JOWGG Sw HO nw 01 WIAA A0 21150550 IXY ML Z0 3G AV BAWA 2 ZION 7S00B8 ZPZPZ ted 555 CON WALI NO Siad TWNOILIOGY 1 i 135 DLW ONITVVA ADH 90 9 ONIEYIL ATA H Shd 0008192 21 2 8 031110 G3ALLINO 1 0 084 im x Ed 336 e BLUE BIRD ACF ALL AMERICAN SERVICE MANUAL RAS 227 for Steer Axle and RAD 227 for Drive Axle RAS 227 Parallelogram Designed Steer RAD 227 Parallelogram Designed Drive Axle Suspension 7 000 15 000 Ib cap Axle Suspension 10 000 25 000 Common replacement parts are shown below For air springs hangers and torque beams refer to your specific installation drawing E m NOTE This new style Momo FCC 7 forged 4 7 16 bush eccentric replaces previous style with square head 9090005 Recaiver ring 3 5 OD 2 28 ID 90030928000 7 Anti tum washer Yo tallati VEI of these i a Enaut 1 1 4 Torque iwo methods FNC sid Beam 90045658000 Locking plate d di 711105128000 pude
12. The wheel hub with either an attached drum or rotor is mounted upon to the axle spindles Axle shafts pass through the center of the spindles and bolt to the outer flange of the wheel hub Thus the rear wheel bearings are lubricated by the axle oil Synthetic axle lubricant is standard Towing the bus with the rear wheels on the road requires removal of the rear axle shafts in order to avoid potential damageto the automatic transmission See Jacking amp Towing in the Specs amp Maintenance chapter for the required procedure Appendixes In This Chapter For Hendrickson Softek suspension service procedures see Front Axle amp Suspension chapter Appendix 1 Appendix 1 Comfort Air Rear Suspension Hendrickson Technical Procedure num ber 17730 246 covers maintenance disassembly adn troubleshooting for the Com fort Air rear suspension Appendix 2 Ridewell Air Rear Suspension Ridewell publication covers mainte nance adjustment and component replacement information on the Ridewell front and rear air suspension On The TechReference CD Rear Axle Arvin Meritor Maintenance Manual 5A includes thorough servicing infor mation on the disassembly inspection and servicing of the rear axles differential and reduction gears The axles used on Blue Bird All Americans are single speed axles without Driver Controlled Main Differential Lock DCDL Also See The Hydraulc Brakes chapter of this manual includes a detailed procedure for r
13. bolts washers and locknuts Tighten 4 locknuts to R 40 50 inch pounds torque 4 Remove jack stands and lower frame of vehicle 5 Air up system 1 BLUE BIRD APPENDIX 0 22 17730 246 REAR AXLE amp SUSPENSION APPENDIXES H COMFORT AIR SHOCK ABSORBER DISASSEMBLY 1 Remove the 2 locknut and washers that connect shock absorber to frame hanger See Figure 7 12 2 Remove the 34 bolt washers and locknut that connect shock absorber to lower shock absorber bracket 3 Remove shock absorber ASSEMBLY 1 Install shock absorber to frame bracket stud by attaching washers and locknut Washers must be installed on each side of shock absorber bushing 2 Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut 3 Tighten 2 locknut to 3 50 70 foot pounds torque and locknut to 3 160 180 foot pounds torque Figure 7 12 z 5 Upper Shock 1 2 Locknut Tightening Torque 50 70 Ft Lbs KR Shock Absorber Lower Shock Lower Shock 34 Locknut Tightening Torque 160 180 Ft Lbs i UPPER SHOCK ABSORBER FRAME BRACKET DISASSEMBLY 1 Remove the 1 2 locknut and washers that connect shock absorber to frame bracket 2 Remove the 34 bolt washers and locknut that connect shock absorber to lower shock absorber bracket 3 Remove shock absorber 4 Remove the fasteners that at
14. bushings over shoot desired final position by 3 16 and press again from opposite side to center the bush ing within the main support member assembly See Figure 7 8 7 Trim all protruding tape from the underside of the eye Wipe off excess lubricant Allow the lubricant four hours to dissipate before operating vehicle 8 Replace the two nylon pucks inside the secondary leaf eye 9 Slide secondary leaf around main support member eye and rotate into position 10 Place one liner between the secondary leaf and the main support member Place the second liner on top of the secondary leaf and tape the assembly together using two x 12 long strips of splicing tape DO NOT WRAP EXCESSIVE TAPE AROUND THE ASSEMBLY AS THIS WOULD CREATE HIGH SPOTS IN THE CLAMP GROUP DO NOT WRAP TAPE AROUND THE ASSEMBLY MORE THAN TWICE FAILURE TO DO SO CAN CAUSE PREMATURE WEAR OR DAMAGE TO THE MAIN SUPPORT MEMBER 11 Install the 7 16 bolt and nut into the spring clip and tighten to A 30 34 foot pounds torque See Figure 7 4 12 Replace main support member assembly per instructions in this section SPRING SEAT BOTTOM CAP The spring seat and bottom cap are unlikely to require replacement In normal use they should function satisfactorily throughout the life of the vehicle Replacement is required when they have been damaged SPRING SEAT DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension VEHICLE
15. MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system and remove height control valve extension rod from valve by removing locknut and washer Remove bolt locknuts and washers See Figure 7 9 Remove bolts axle bottom cap and top pad Loosen the 34 bolts washers and locknuts that connect the cross channel to both main support assemblies 7 Lift cross channel and the main support member assembly with a jack 8 Remove spring seat Das 19 1 APPENDIX 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL COMFORT AIR Figure 7 9 308 Main Support Member Assembly Spring Seat Lower Shock Bracket Axle Bottom Cap 7 8 Locknut 34 Locknut 7 Tightening Torque Tightening Torque 34 10UNC Locknuts 400 450 ft Ibs 285 305 ft Ibs Cross Tightening Torque Channel 260 320 ft Ibs SPRING SEAT ASSEMBLY 1 Install spring seat on axle in proper direction 2 Position main support assembly on spring seat or on spacer plate if so equipped with main support assembly center dowel pin piloting into hole in spring seat or spacer plate Delrin liner must be positioned on the topside of the main support member assembly 3 Assemble U bolts axle bottom cap washers and locknuts DO NOT TIGHTEN U bolt locknuts at this time 4 Tighten the 34 bolts washers and locknuts that con
16. a level surface Apply the parking brakes Chock the wheels opposite those being lifted Using a jack or lift of sufficient strength lift the bus to take the wheels off the floor Place jack stands of sufficient strength under the frame rails forward of the front spring hanger brackets 2 Remove rear wheels 3 Disconnect the driveline at the differential by removing capscrews and u joint straps 4 Suspend the driveline safely out of the way 5 Disconnect the wheel speed sensors 6 If bus is equipped with hydraulic brakes disconnect the hydraulic lines at the frame rails 7 If bus is equipped with air brakes release the air pressure from the air tanks Then disconnect the air lines at the chassis frame rail 8 Remove Shock Absorber as follows 8 1 8 2 8 3 Lift the axle suspension assembly enough to take the weight off the suspension hangers Remove hexnut flat washers and bolt from the bottom end of the shock absorber Remove hexnut flat washers and bolt from the top end of the shock absorber The shock absorber can now be removed REAR AXLE amp SUSPENSION When reinstalling shock abosrbers torque the bolts to 75 100 ft 102 135 Nm Use the longer bolt at the bottom of the shock absorber Install the top bolt with its head toward the front of the vehicle Install the bot tom bolt with its head toward the rear 9 Remove the stabilizer bar if so equipped by removing locknut
17. also required 1 Remove the 7 16 bolt clip bolt spacer and nut from the secondary leaf spring clip 2 the splicing tape that holds the liners to the center of the main support member assembly and rotate the secondary leaf to clear the spring clip from main support member 3 Slide the secondary leaf off of the main support member eye 4 Support the main support member on the receiving tool with the end hub centered on tool Be sure the main support member 15 squarely supported on the press bed See Figure 7 5 17730 246 17 1 APPENDIX BLUE BIRD 0 306 0 BLUE BIRD APA SERVICE MANUAL COMFORT AIR H NOTE 1 APPENDIX At the time of manufacture a spring eye clip was used to insert the pivot bushing into the spring eye of the the main support member See Figure 7 6 If spring eye clip is equipped on the main support member you have the option to carefully press out the bushing from the opposite side of the spring eye where the spring eye clip is NOT visible If the spring eye clip is not damaged it can be used again to facilitate the pressing in of the pivot bushing into the spring eye If clip is damaged use the tape option as shown in Figure 7 7 Figure 7 6 Main Support Member Pivot Bushing Spring Eye Clip 5 Center the push out tool on inner sleeve and press out the old bushing These bush ings are not cartridge type bushings They do n
18. i i 2 APPENDIX BLUE BIRD 322 e BLUE BIRD SERVICE MANUAL CONTENTS Basic Operation Operational Inspection Preventative Maintenance Basic Troubleshooting Axle Alignment Procedure Bushing Replacement Procedure Ride Height Height Control Valve Adjustment Shock Absorber Adjustment Parts Illustrations SUSPENSION IDENTIFICATION Ridewell Suspensions are identified by a metal tag welded to the left hand hanger that indicates part number model number capacity and date of manufacture Consult your vehicle manufacturer for your correct mounting height PARTS For optimum suspension performance order only Ridewell parts Replacement parts for Model RAS 227 RAD 227 RAD 227C and RAD 227WB are shown in Section 9 of this manual SALES SERVICE amp WARRANTY If you need assistance regarding this product please contact us and we will be glad to help you Mailing Address Shipping Address Phones Fax email Ridewell Corporation Rideweli Corporation 800 641 4122 417 833 4565 P O Box 4586 3715 E Farm Rd 94 417 833 4560 fax Springfield MO 65808 Springfield MO 65803 info ridewellcorp com 2 APPENDIX REAR AXLE amp SUSPENSION APPENDIXES BASIC OPERATION When properly maintained and operated within design limits Ridewell s RAD 227 Drive Axle RAS 227 Steer Axle and RAD 227WB Drive Axle Wide Base will provide many years of trouble free service The
19. single reduction speed with synthetic bearing lubrication Standard model is RS21 145 21 000 Ib GAWR 5 29 1 reduction ratio All American FE may be equipped with optional models depending upon GVWR and reduction ratio suspension and or brakes options Meritor Model GAWR Details RS19 144 19 000 165 RS21 145 21 000 lbs Standard RC23 160 23 000 Ibs RS23 160 23 000 Ibs Rear Engine Rear Axle Meritor single reduction speed with synthetic lubed bearings Standard model is RS23 160 23 000 Ibs capacity 5 38 to 1 ratio All American RE may be equipped with optional models depending upon GVWR and reduction ratio suspension and or brakes options Meritor Model GAWR Details RS19 144 19 000 Ibs RS21 145 21 000 Ibs RC23 160 23 000 Ibs RS23 160 23 000 lbs Standard REAR AXLE amp SUSPENSION gt Single Reduction Rear Differential Carriers Maintenance Manual 5A 267 Single Reduction Rear Differential Carriers Meritor Publication Maintenance Manual 5A The specific axle model installed may be identified by refering to the axle data plate affixed to driveshaft side front on Forward Engine rear on Rear Engine of the axleS housing RIDEWELL SUSPENSION 2 APPENDIX COMFORT AIR REAR SUSPENSION 1 0 APPENDIX BLUE BIRD 268 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Whether the bus is equipped with air or hydraulic brakes wheel hubs and brake drums or rotors are mounted similarly
20. support member assembly 2 Assemble the top pad U bolts axle bottom cap washers and locknuts DO NOT TIGHTEN U bolt locknuts at this time see Figure 7 4 WARNING DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY 3 Install NEW QUIK ALIGN collars NEW 1 dacromet pivot bolt washers and locknut Verify the nose of each QUIK ALIGN collar is installed into the pivot bushing sleeve and the flanged collar is flat against the hanger face within the adjustment guides DO NOT TIGHTEN at this time NOTE The eccentric collar is located on the outside frame on the left side of chassis with the 1 APPENDIX concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger 4 Position shock absorber and lower mounting bracket assembly on main support assembly b Position cross channel on main support assemblies Install 34 bolts washers and locknuts Tighten to 3 260 320 foot pounds torque 6 Snug 1 NEW QUIK ALIGN locknuts to 100 foot pounds torque Figure 7 3 7 Tighten the U bolt locknuts evenly and tighten to the proper torque in the proper sequence see Figure 7 3 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m
21. vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system and remove height control valve extension rod from valve by removing locknuts and washers 4 Mark the position of QUIK ALIGN collar on the frame hanger SERVICE HINT Marking the position will create a starting point for the alignment procedure following assembly 5 Remove the 1 pivot bolt nut and QUIK ALIGN collars that connect the main support member assembly to the frame hanger see Figure 7 2 6 Remove the U bolts locknuts and washers 7 Remove the axle bottom cap and top pad 8 Remove the 34 bolts washers and locknuts that connect the cross channel both main support assemblies 9 Lift cross channel off of the main support assemblies with jacks 17730 246 15 1 APPENDIX 0 BLUE BIRD 304 0 BLUE BIRD lt ALL AMERICAN SERVICE MANUAL COMFORT AIR 10 Lift and rotate the shock absorber and lower mounting bracket away from the main support assembly to be replaced 11 Remove the main support assembly ASSEMBLY 1 Position main support member assembly on spring seat or on spacer plate if equipped with the main support member assembly center dowel pin piloting into hole in spring seat or spacer plate Galvanized steel liner must be positioned on the topside of the main
22. 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to R 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to A 285 305 foot pounds torque 8 Remove jack stands and lower the frame of vehicle 9 Install upper extension rod stud onto the height control valve arm Tighten locknut to A 80 90 inch pounds torque 10 Air up the system 11 Align rear axle see alignment in the Preventative Maintenance Section of this publication 16 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 5 COMFORT AIR Figure 7 4 Frame Hanger ff Concentric U Bolt Collar Eccentric Collar U Bolt I Yt 8 I 1 Washer Top Pad 1 MM Bolt E ix Tm enue Ge NS Tightening Torque Puck MT ef 525 575 ft Ibs 7 ping BSS by ax e Pivot Bushing Q q i 9898 Cee NN Cross Channel Clip Bolt Spacer Spacer if equipped Spring Seat Lower Shock Locknut 160 180 1 Lbs Lower Shock Bracket 34 Locknut Tightening Torque 260 320 ft Ibs MAIN SUPPORT MEMBER ASSEMBLY PIVOT BUSHING Figure 7 5 DISASSEMBLY Use a vertical shop press with a capacity of at least 10 tons A long piece of 4 1 0 by 25 wall steel tubing receiving tool is required A 6 long piece of 13 4 O D round bar stock with 11 2 x 13 8 O D machined pilot push out tool is
23. 270 3 34 Rear Engine 20 60 75 100 ft Ibs 75 100 ft Ibs i 280 310 ft Ibs 0077616 REAR AXLE amp SUSPENSION Rear Softek Suspension Installation 1 Install spring hanger brackets items 10 amp 11 as shown 2 Install pad assembly item 13 using fasteners shown The pad assembly should be installed so that the bracket makes contact with the bottom of the frame rail before tightening fasteners 3 Place springs in the rear suspension installation jig with the radius leaf to 271 ward front of chassis 4 Select proper axle per production order 5 install saddle 5 over axle dowels at 40 00 spring centers 6 Place axle housing on axle saddles item 5 w axle centered on springs To center axle housing measure distance between outside edge of spring stack and inboard face of brake mtg Flange see detail a for both left amp right sides Move axle side to side if required until difference of left amp right measurement is 38 or less Axle saddle item 5 is to remain centered on spring item 7 7 Square axle saddle with axle housing 06 at outer edge of pad 8 Install u bolt bracket 4 and spherical washers 9 Install u bolts item 9 with u bolt seat item 8 between u bolts and top of spring Note u bolt length variations by model 10 Install shock on shock arm of bracket item 4 as shown in diagram 11 Use hardened flat washer and hi nut on ends of u bolts To
24. 4 from center loosen fasteners item 24 and add shims item 16 as req d Add only equal number of shims on each side of spring Tighten fasteners and re check alignment Re peat step until laser mark is within 1 4 of center 18 3 torque fasteners 100 125 ft lbs See appropriate fuel tank amp barrier installation diagram for part numbers and fasteners Due to initial relaxation and or seating of suspension to axle connection hardware retorquing of nuts on suspension u bolts items 9 prior to deliv ery is required A minimum of two tightenings one at initial assembly amp one after body mount It is preferable to do second one after road test but any time after body mount is acceptable REAR AXLE amp SUSPENSION 273 0 BLUE BIRD BLUE BIRD SERVICE MANUAL Vision outside on Axle Centerline rn H n H rm Mounting Flange viewed from rear Centering Axle on Frame Measure from outside face of frame rail web to brake mounting flange edge of brake drum or edge of new tire Measure both sides of chassis Measurements should be equal within 4 0040114 REAR AXLE amp SUSPENSION Torque Requirements KEY DESCRIPTION TORQUE A U bolt High Locknut 7 8 14
25. 62 62000 Transverse Rod Assy Specify Length 27 Spring Seat 2 63 49689 000 Torque Rod Shim As Req Meritor RS15 120 64 22186 000 Transverse Rod Frame Bracket 57022 010 4 5 Pinion Angle LH RH Meritor RS21 145 RS23 160 56501 006 4 5 Pinion Angle LH RH 56501 019 0 0 Pinion Angle LH RH SERVICE KITS QUICK REFERENCE 56501 020 4 5 Pinion Angle LH RH 56501 021 0 0 Pinion Angle LH RH 60632 001 QUIK ALIGN Kit Meritor RC23 160 34013 103 Pivot Bushing Service Kit 56501 020 Negative 4 5 Pinion Angle LH RH 49175 026 Spring Clip Fastener Kit 28 Axle Bottom Cap 2 50763 004 Cross Channel Fastener Kit Meritor RS15 120 49177 006 Air Spring Fastener Kit 57024 000 2 5 0 Pinion Angle LH RH 59013 000 Height Control Valve Kit Meritor RS21 145 RS23 160 Lower Control Valve Link Kit 502 16 000 0 9 5 Pinion Angle LH RH 57430 000 All Except Rear Engine Meritor RC23 160 57430 003 Rear Engine Only 50216 000 Negative 0 9 5 Angle LH RH 48718 U Bolt Kit Specify Length 29 Cross Channel 1 48718 104 U Bolt Kit 15 000 Ib Capacity Contact Tech Services for proper Cross Channel 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 5 1 APPENDIX 0 BLUE BIRD 296 0 BLUE BIRD lt ALL AMERICAN SERVICE MANUAL COMFORT AIR SECTION 5 H Preventative Maintenance 1 APPENDIX MAIN SUPPORT MEMBER ASSEMBLY BUSHINGS Bushings should function satisfactorily during normal vehicle operation How
26. ALVE ADJUSTMENT Operation As load is applied the horizontal actuating lever arm moves from neutral position to up intake position As load is removed the horizontal actuating lever arm moves from neutral position to down exhaust position The valve opens and air is allowed to exhaust from air springs bringing the horizontal actuating lever back to a neutral position Optimum performance is achieved when valve is adjusted accurately to the suspension by increasing or decreasing horizontal lever arm length to a point where valve and lever arm approach 45 degrees maximum up or down from neutral position Adjustment 1 With vehicle on level ground build and maintain supply air pressure in excess of 65 p s i 2 Loosen vertical link hose clamp to allow P shaped rubber connector to slide freely up and down vertical link 3 Rotate horizontal lever arm down to exhaust air springs or rotate up to inflate springs until proper ride height is achieved 4 Tighten hose clamp on vertical link connector while holding horizontal lever arms in neutral position 5 TEST Disconnect vertical link rod grommet from pin bracket at axle Rotate horizonta lever arm down to exhaust air springs about halfway Rotate horizontal lever arm up until grommet is back to pin bracket level Air springs should re inflate to ride level height 6 Re connect grommet to pin Check to see if air springs are of equal firmness Make sure vertical link rod extends complet
27. Air supply a Plug this D 7 Ay i ET Na P Dump Control Drs swith gt s cab TS B CS CS BSS A Airline S A E SI BEN SR D O T Compliant E B 35 2 B AS All others hoses 8 inch LN B AL Sa ae lt B Cm Ds ul UIS m uo 28 17730 246 1 BLUE BIRD APPENDIX 0 H REAR AXLE amp SUSPENSION APPENDIXES gt COMFORT AIR SECTION 9 Troubleshooting Guide COMFORT AIR TROUBLE SHOOTING GUIDE CONDITION POSSIBLE CAUSE CORRECTION Vehicle bouncing excessively Leaking shock absorber Replace shock absorber Damaged shock absorber Replace shock absorber Air spring s not inflated Check air supply to air spring repair as necessary ncorrect ride height Adjust ride height to proper setting See Ride Height Setting in the Preventative Maintenance Section of this publication Suspension has harsh or bumpy ride Broken main support member assembly Replace main support member assembly Damaged height contro valve Replace height control valve Excessive driveline vibration ncorrect ride height Adjust ride height to proper setting See Ride Height Setting in the Preventative Maintenance Section of this publication Broken main suppor
28. D TCFE FLAT FLOOR 4 7 8 22 75 BLUE BIRD HDRE 47 8 22 75 BLUE BIRD 4 7 8 22 75 Figure 5 2 7 Use a 1 8 wooden dowel rod golf tee to set the neutral position for the height con trol valve by aligning hole in leveling arm with hole in control valve cover as shown in Figure 5 3 DO NOT use a metal rod or nail as this may cause damage the height control valve Figure 5 3 To set neutral position 8 Reposition the extension rod in the rubber align hole with hole on joint height control valve cover 9 Attach washer and locknut and tighten to Aj 80 90 inch pounds torque 10 Tighten clamp on the rubber joint with a screwdriver until securely fastened NOTE During cycle operation of the height control valve it is normal to experience a limited amount of exhaust noise 17730 246 9 1 APPENDIX 0 BLUE BIRD 298 0 BLUE BIRD IF E ALL AMERICAN SERVICE MANUAL COMFORT AIR TRANSVERSE RODS p H The length of the transverse rod is determined by the vehicle manufacturer in order to cen ter the axles under the frame The transverse rod maintains lateral axle position during cor nering See Figure 5 4 The mounting bracket at the axle end of the torque rod is furnished and welded into position on the axle housing by the axle or vehicle manufacturer Figure 5 4 Bracket Supplied by Axle Manufacturer Torque rod end attaching fasteners are furnished by the vehicle manufacturer It is
29. DAMAGE TO THE MAIN SUPPORT MEMBER ASSEMBLY COULD FAIL AND CAUSE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE 4 17730 246 H WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR PROCEDURES AND TOOLS A TECHNICIAN USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE VEHICLE S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED WILL ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED SHOCK ABSORBERS THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SUSPENSION ANYTIME THE AXLE ON A COMFORT AIR SUSPENSION IS SUSPENDED IT IS MANDATORY THAT THE SHOCK ABSORBERS REMAIN CONNECTED FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO SEPARATE FROM THE PISTON AND RESULT IN PREMATURE AIR SPRING FAILURE PERSONAL PROTECTIVE EQUIPMENT ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTENANCE REPAIR OR SERVICE PARTS CLEANING SOLVENT CLEANERS CAN BE FLAMMABLE POISONOUS AND CAUSE BURNS TO HELP AVOID SERIOUS PERSONAL INJURY CAREFULLY FOLLOW THE MANUFACTURER S PRODUCT INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURES 1 WEAR PROPER EYE PROTECTION 2 WEAR CLOTHING THAT PROTECTS YOUR
30. HSNI F 1 X 81 5 ON 91 S E 20195108911 SL JL LX ON wo 6 1 V Oea ODUSZGZVEZL LT OND ANY HW 10098861 SL ft LAN 8 3414 X3H 2090801 7 3000 Nivea 00699605521 i X 038 2458 SOCGOGEFCZI LE Of QOAZL SASSY Sen ae 4 90052 1 X 1 NNOO i LL GENL t i X 571 17884 NNOD 5900521 5 LIN 71 JiddiN 9 B L X COUTZL 2 T nsss 100062 S9 IN 133818 33L ZZESOSZPEEL 5 ad ay Bv dH v71 080020 803 Ney 51399 ML L dMOS 2212 1200001 QuifiD3u Slav IRD m BL 2s a SERVICE MANUAL 1 301 uam BS BY 00258292081 EE mam ES ISCTXV 5 5 5 335 venom 03 SJAA
31. K ALIGN d Concentric Collar Pivot Bushing Puck 13 1 APPENDIX 0 BLUE BIRD SERVICE MANUAL COMFORT AIR 7 Component Replacement FRAME HANGER The frame hanger should function satisfactorily during normal vehicle operation 302 Replacement is required when the frame hanger has been damaged or worn DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the dacromet locknut and washers 1 pivot bolt and QUIK ALIGN collars that connect main support member assembly to frame hanger see Figure 7 1 5 Remove the fasteners that attach the frame hanger to the vehicle per vehicle manufac turer specifications 6 Remove frame hanger Figure 7 1 Frame Hanger 1 Washer QUIK ALIGN Eccentric Collar K 1 Washer P 1 8UNC 7 5 Bolt 1 Locknut S S QUIK ALIGN Tightening Torque XS Concentric Collar 525 575 ft 5 Or Pivot Bushing Main Support Member 1 Install new frame hanger by attaching fasteners per vehicle manufacturer specifica tions 2 Install the new QUIK ALIGN collars new 1 dacromet pivot bolt washers and locknut that attach the mai
32. Locknut 2 5 16 80 90 in Ibs 11 Air Spring to Frame Bracket Locknut 2 1 2 20 30 12 Main Support Member Assembly Spring Clip Nut 2 7 16 30 34 NOTE 1 Follow torque specifications furnished by Truck Manufacturer s for OEM supplied fasteners The torque values listed above apply only if Hendrickson furnished fasteners are use 17730 246 31 1 0 APPENDIX BLUE BIRD SERVICE MANUAL 320 Information contained in this literature was accurate at the time of publication Product changes may have been made eoe oat are Truck Suspension Systems 630 910 2800 The Boler Company 800 S Frontage Road FAX 630 910 2899 Copyright 2001 www hendrickson intl com All Rights Reserved 17730 246A 2M 12 01 Printed in United States of America Woodridge IL 60517 4904 1 BLUE BIRD APPENDIX 0 REAR AXLE amp SUSPENSION APPENDIXES Service Manual for p Air Ride 227 Series SUSPENSIONS MODELS RAD 227 RAD 227C RAD 227WB AND RAS 227 RAD 227C 100 Air Ride Cap 34 000 48 000 Ibs RAD 227 Cap 10 000 25 000 165 RAS 227 Cap 7 000 15 000 Ibs RAD 227WB Wide Base 100 Air Ride Cap 10 000 25 000 Ibs i i i i Revised 11 2006 Ridewell Corporation e 4586 e Springfield 65808 800 641 4122 417 833 4565 417 833 4560 www ridewellcorp com i
33. OL PROPERTY DAMAGE OR SEVERE PERSONAL INJURY MAINTAIN CORRECT TORQUE VALUE AT ALL TIMES CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED LOAD CAPACITY ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION ADD ON AXLE ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED AND APPROVED CAPACITIES WHICH CAN RESULT IN COMPONENT DAMAGE AND LOSS OF VEHICLE CONTROL POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE MODIFYING COMPONENTS DO NOT MODIFY OR REWORK PARTS DO NOT SUBSTITUTE PARTS OF THE SUSPENSION USE OF MODIFIED OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY NOT MEET HENDRICKSON S SPECIFICATIONS AND CAN RESULT IN COMPONENT DAMAGE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS DO NOT MODIFY PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON TORCH WELDING DO NOT USE A CUTTING TORCH TO REMOVE ANY ATTACHING FASTENERS THE USE OF HEAT ON SUSPENSION COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF THE MAIN SUPPORT MEMBER DO NOT CONNECT ARC WELDING GROUND LINE TO THE MAIN SUPPORT MEMBER DO NOT STRIKE AN ARC WITH THE ELECTRODE ON THE MAIN SUPPORT MEMBER ASSEMBLY AND AXLE DO NOT USE HEAT NEAR THE MAIN SUPPORT MEMBER ASSEMBLY DO NOT NICK OR GOUGE THE MAIN SUPPORT MEMBER ASSEMBLY SUCH IMPROPER ACTIONS CAN CAUSE
34. OUNO DATH estis ei POD v soe du aur act isd oc 8 OL 125 WWA ONIG NOLO een M GER ENIUGS aly 2 OL 0310207 BG AVW HI WOWINIW NIRU 828 SLID BOWES Sv ATIVELY YO OL GBHSINENS 58401519 AVW TOULNOD LHOISH TEO 03132405 GSNOOTIWE ADNO ASIN HEWMOISDID Dit SUNILILJ ONY IXY WIOL 504 2 ALON 775090509 Led 355 uly ON WALI NO Siad WNOILIOOV Od 1 APPENDIX 2 155 1 9 ONT VA EINEN 1 NGEROS A ATA Ni 42 id 5 589 0008192 beet GAL 594141115 8 ASM rd 8 034 im 1 ON 334 REAR AXLE amp SUSPENSION APPENDIXES BLUE BIRD 00 19567102 xe 31v0 T NOLLdluOS3d NOISY 299 icxdcdas stunts moreno Gui Ce RS wa 16 52 00 OL Wil 40 YUN Q3Qvuodn t 9 enupides2o BUNAD
35. Only Shock Absorber Upper Shock Shock Absorber Lower Shock Linkage Rod Assy Locknut Leveling Valve Mounting Capscrew 5 8 11 Gr8 Air Spring Stud Nut 3 4 16 Hanger Assembly Nut 3 4 10 TORQUE 400 450 ft lb 260 320 ft lb 20 30 ft lb 525 575 ft lb 525 575 ft lb 100 16 during alignment 50 70 ft lb 160 180 ft lb 100 150 ft lb 60 85 ft lb 90 122 Ft lbs 25 Ft lbs 155 210 Ft lbs 277 0 BLUE BIRD H6ctcvoOo ee SN 2 S CN T a lt S Bottom of frame rail Top of mounting plate 8 00 25 See Ride Height Adjustment Rear Ridewell Suspension Rear Engine IF lt E 5 lt e lt ef REAR AXLE amp SUSPENSION Torque Requirements KEY UA gt DESCRIPTION Air Spring Stud Nut Air Spring Stud Nut U Bolt Nuts Sway Bar L Nut Hanger Beam L Nut Hex Nut 1 2 13 Grd 8 Hex Nut 5 8 11 Grd 8 Suspension Hanger Hex Nut 3 4 10 Grd 8 TORQUE 25 ft lb 50 ft lb 350 ft lb 460 ft lb 1000 16 56 ft lb 160 180 ft Ib 155 210 ft lb 279 0 BLUE BIRD SERVICE MANUAL Ride height Ride height is defined as the distance between the axle and the bottom of the frame rail and may be verified by measuring ei
36. PENDIX BLUE BIRD 326 e BLUE BIRD SERVICE MANUAL BASIC TROUBLESHOOTING NOTE Do not check system until minimum 65 p s i air pressure is built and maintained 1 All Air Springs Flat or Slow to Fill Check the following a Air pressure b Air brake protection valve c Height control valve 2 Air Springs Flat on One Side of Suspension Check the following a Air springs b Height control valve C Height control valve setting 3 When Vehicle is Parked Suspension Deflates Rapidly Check the following a Airlines b Air springs 4 Vehicle Pulls to Left or Right Check the following a Tire pressure b Axle alignment c Suspension bushings 5 Vehicle has Excessive Sway Check the following a Air springs firmness b Sway bar bushings c Torque beam bushings 2 APPENDIX REAR AXLE amp SUSPENSION APPENDIXES AXLE ALIGNMENT PROCEDURES Procedure 1 For suspensions with eccentric bolts only 1 Loosen all 1 4 eccentric bolt nuts 2 Remove anti turn washers from head of eccentric bolts 3 Align axle by turning eccentric arrow head the lower most torque beam to the direction the axle needs to move 4 Turn the upper eccentric arrow to the same position of the lower arrow Check alignment and 5 After alignment is achieved install anti turn washers to eccentric bolt heads 6 Tight
37. RAD 227 series suspensions have several unique features which keep maintenance to a minimum and performance at a maximum 1 100 ride on air 2 Parallelogram design promotes road stability allowing axle movement with no change in steering or drive line angle 3 A patented eccentric bolt and or screw rod feature allows for simple positive axle alignment 4 Rubber bushed pivot points require no lubrication 5 A self contained shock absorber that allows precise installation and insures proper shock and air spring tolerance Air Springs amp Height Control Valve Your air ride suspension is designed to dampen the shocks transmitted from road surface to vehicle frame through the air springs The height control valve is used to maintain the volume of air in the air springs You may use a single valve system to maintain ride height only or use a double system to maintain ride height and level the vehicle Please check with your vehicle manufacturer for your suspension s ride height The air springs used on Model 227 suspensions have internal rubber bumpers designed to carry the vehicle load should air spring failure or sudden loss of air supply occur Should an air spring fail single height contro valve system all of the air springs will deflate allowing the suspension to oper ate on internal bumpers until repairs can be made Should an air spring fail on a double h
38. S C3UNVHaOdd3d 03 LHS 38 LSNA SNOLJSNNDO L3 21 01 OL SONLLU TW NO 1497935 Jdid ISN 7 5 G3ON3RIOO3H C 340539 LOSNNOOSIO ISNS AWA AVIS NO SNITINd SASSSOxS 3598 WOHi A134 SAOWSY OL SI u3AQOMGNOS Y c NO O3UNGMIOOSH 359349 214109730 1 SSGLON ANKE E eir x Ts Ds SM WCWAINIAL 3HlM 39049 8 ISN 3503 SE AcE OL 29788 40 3578 HAWS znss3Hd DI ame Z vo vi annaus DI OM Z vl HAWS ZHOSEJHd 28 ANAA SNC 112 NO UNDOND SNOT 2 8 Zi Ol 87 ONDI L4 Z SOLON Ol 02 Xvid INOT L4 Z B APPENDIX BLUE BIRD REAR AXLE amp SUSPENSION APPENDIXES HIA SUOSSAHANOD dH W T L SALON NOLO AIBM3SSV 5 MW mu SEN 326 38 30745 0301530 Si HOLS 312201
39. SKIN 3 WORK IN A WELL VENTILATED AREA 4 DO NOT USE GASOLINE OR SOLVENTS THAT CONTAIN GASOLINE GASOLINE CAN EXPLODE 5 HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY FOLLOW THE MANUFACTURER S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY TO HELP PREVENT PERSONAL ACCIDENT OR INJURY DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR POLISHED PARTS DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY QUIK ALIGN FASTENERS DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY ENSURE THAT QUIK ALIGN FASTENERS TORQUE VALUE IS SUSTAINED AS RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION FAILURE TO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE 1 APPENDIX 0 BLUE BIRD SERVICE MANUAL SECTION 4 Parts Lists H COMFORT AIR 294 lt gt NG gt 62 Bracket Supplied by Axle Manufacturer 6 17730 246 BLUE BIRD APPENDIX COMFORT AIR KEY NO PART NO DESCRIPTION NO REQ KEY NO PART NO DESCRIPTION NO REQ 60784 000 Frame Hanger 2 57356 000 Lower Shock Bracket Assy 2 2 60632 001 QUIK ALIGN Kit Includes Key Nos 3 7 1 Includes Key Nos 30 33 34013 103 Pivot Bushing
40. STENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY ENSURE THAT QUIK ALIGN FASTENERS TORQUE VALUE IS SUSTAINED AS RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION FAILURE TO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE m Measure from straight edge to forward face of axle arm to verify both sides of axle are equal and tighten the 1 QUIK ALIGN locknuts to 3 525 575 foot pounds torque NOTE The Eccentric collar is located on the outside frame on the left side of chassis with the concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger NOTE 17730 246 Axle adjustment is applied to LEFT side of vehicle only If adjustment to the right side of vehicle is necessary it will require replacement of the outside concentric collar with an eccentric collar Hendrickson Part No 64096 000 and repeat step 7 on the right side of vehicle 8 Following alignment of axle move vehicle back and forth several times prior to remov ing straight edge from frame and recheck measurements to confirm adjustments 9 Repeat steps 7 and 8 until alignment is achieved Figure 6 2 Frame Hanger QUIK ALIGN Eccentric Collar 1 Washer 1 8UNC 7 5 Bolt 1 Locknut gt Tightening Torque 525 575 11 Ibs QUI
41. Service Kit Includes Key 30 Lower Shock Bracket 2 Nos 3 6 7 13 15 Services 1 Side Only 31 50764 002 3 4 1OUNC 5 50 Bolt 2 3 64107 000 1 8UNC 7 50 Bolt 2 32 22962 001 3 4 Hardened Washer 4 4 64097 000 QUIK ALIGN Concentric Collar 3 33 49842 000 3 4 10UNC Locknut 2 5 64096 000 QUIK ALIGN Eccentric Collar 1 50763 004 Cross Channel Fastener Includes Key 6 22962 035 1 Hardened Washer 4 Nos 34 37 7 64108 000 1 8UNC Locknut 2 34 50764 003 3 4 1OUNC 3 50 Bolt 2 60925 002 Air Spring Assy Includes Key Nos 9 11 2 35 50764 005 3 4 1OUNC 3 00 Bolt 2 60929 002 Air Spring Assy Front Engine Includes 2 36 22962 001 3 4 Hardened Washer 8 Key Nos 9 11 37 49842 000 3 4 1OUNC Locknut 4 8 Air Spring 2 38 49177 006 Air Spring Fastener Kit Includes 9 57096 002 Air Spring Hanger 2 Key Nos 39 40 10 22962 014 Washer 2 39 22962 014 1 2 Hardened Washer 2 11 17700 010 1 2 13UNC Nylocknut 2 40 17700 010 1 2 13UNC Nylocknut 2 60779 000 MSM Assy Includes Key Nos 12 20 2 41 60998 001 Shock Absorber 2 12 Main Support Member 2 42 57322 002 Upper Shock Frame Bracket Assembly 2 13 58648 000 Pivot Bushing 2 Includes Key Nos 43 45 14 37674 051 Liner 4 43 Shock Frame Hanger 2 15 64817 000 Puck 4 44 50368 000 1 2 13UNC Serrated Shank Bolt 2 49175 026 Spring Clip Fastener Kit Includes Key 45 22962 031 1 2 Hardened Washer 2 Nos 17 18 Washer 19 46 49846 000 1 2 13UNC Locknut 2 16 Secondary Leaf 4 47 59013 000 Height Control Va
42. Shock Mount 17730 246 11 1 APPENDIX 0 BLUE BIRD 300 0 BLUE BIRD lt ALL AMERICAN SERVICE MANUAL COMFORT AIR 6 Alignment ALIGNMENT Proper alignment is essential for maximum ride quality performance and tire service life The recommended alignment procedure is described below This procedure should be per formed if excessive or irregular tire wear is observed or any time the Main Support Member Assembly is removed for service The following procedure should be performed after all repairs are completed NOTE It is important fo have the QUIK ALIGN locknut pre torqued 10 3 100 foot pounds on the left side of vehicle only All other suspension fasteners tightened to their specified torque values The total range of adjustment is 1 0 NOTE Use a new QUIK ALIGN kit Part No 60632 001 for any axle alignment or disassembly of 1 APPENDIX the QUIK ALIGN connection This ensures proper torque is applied to the connection 1 vehicle on level floor 2 and center all suspension joints by slowly moving the vehicle back and forth with out applying the brakes When coming to a complete stop make sure the parking brakes are released 3 Chock front wheels of vehicle 4 Verify proper ride height is set For proper ride height instructions see Ride Height Adjustment in this section of this publication Figure 6 1 2 Angle m
43. Unf 2b 425 Ft lbs 3 4 16 Unf 2b 290 Ft lbs B Cross Channel To Main Support Mbr 3 4 10 Unc 2b 290 Ft lbs C Air Spring To Cross Channel 1 2 13 Unc 2b 25 Ft lbs D Quick Align Joint Right Side Only 1 8 Unc 2b 550 Ft lbs E Quick Align Joint Left Side Only 1 8 Unc 2b 550 Ft lbs 100 Ft Ibs During Alignment F Shock Absorber Upper Shock 1 2 13 Unc 2b 60 Ft lbs 275 G Shock Absorber Lower Shock 3 4 10 Unc 2b 170 Ft lbs H Linkage Rod Assy Locknut 5 16 24 Unf 2b 125 In Ibs J Leveling Valve Mounting 1 4 20 Unc 2b 72 In Ibs K Capscrew 5 8 11 Gr8 110 Ft lbs L Air Spring Stud Nut 3 4 16 25 Ft lbs M Hanger Assembly Nut 3 4 10 175 Ft lbs 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 2 6 Centering Axle on Frame Measure from outside face of frame rail web to brake mounting flange edge of brake drum or edge of new tire Measure both sides of chassis Measurements should be equal within 4 Axle Centerline Mounting Flange viewed from rear 0040115 BLUE BIRD REAR AXLE amp SUSPENSION Torque Requirements KEY OA gt DESCRIPTION U bolt High Locknut Cross Channel To Main Support Mbr Air Spring To Cross Channel Quick Align Joint Right Side Only Quick Align Joint Left Side
44. acement of Torque Beam Bushings 10 11 12 13 14 Lift frame of vehicle with proper jacks or stands and exhaust air from suspension system Remove tires from axle Block axle with proper jacks or stands Remove anti turn washers from heads of eccentric bolts Remove weld from clamp block Remove 1 74 nuts on eccentric bolts Turn eccentric bolt arrow to 12 o clock position and tap out Caution Do Not Damage Threads Remove 1 cap screws from lower beam assembly Remove torque beams from suspension and press bushings out in hydraulic press Using an approved rubber lubricant press in new bushings Make sure bushings are centered in torque beam sleeve Install torque beams into suspension Move axle up or down to proper ride height and torque 1 72 cap screws to 1 100 ft Ibs Re install eccentric bolts and the 1 74 nuts Align axle see Section 5 Install anti turn washers after alignment Torque 1 74 nuts to 1 000 ft Ibs Procedure 2 Replacement of Adjustable Torque Arms or Sway Bar Bushings Remove 1 bolts from torque arms or sway Remove torque arms or sway bar and using an approved rubber lubricant re bush making sure bushings are centered in sleeves Instali torque arms or sway bar Tighten 1 cap screws to 360 ft Ibs torque Align axle if required see Section 5 2 APPENDIX REAR AXLE amp SUSPENSION APPENDIXES RIDE HEIGHT HEIGHT CONTROL V
45. ain support member assembly on the affected side Loosen the 34 bolts washers and locknuts on the opposite side 8 Remove lower shock absorber bracket ASSEMBLY 1 Install the lower shock absorber bracket to the cross channel and main support mem ber assembly by attaching the 34 bolts washers and locknuts Tighten 34 locknuts to 3 260 320 foot pounds torque 2 Install shock absorber to frame bracket stud by attaching washers and Y2 locknut Washers must be installed on each side of shock absorber bushing 3 Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut 4 Tighten locknut to 50 70 foot pounds torque and 34 locknut to 160 180 foot pounds torque 5 Remove jack stands and lower frame of vehicle 6 Airup system 24 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR RIDE HEIGHT CONTROL VALVE DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 13 3 Verify air is removed from the system 4 Remove the 5 16 washer and locknut that attach the extension rod to the ride height control valve arm 5 Remove the air lines from the ride height control valve 6 Remove the brass fittings from the ride height control valve 7 Remove the w
46. angers 2 APPENDIX REAR AXLE amp SUSPENSION APPENDIXES PREVENTATIVE MAINTENANCE DAILY Check for loose or broken parts on or around suspension to prevent any serious problems from occurring EVERY 30 DAYS Check clearances around all moving suspension parts air springs tires and shock absorbers Any signs of interference should be immediately corrected Visually inspect axle beam bolted connection to make sure bolts are tight and there are no signs of wear EVERY 90 DAYS amp WITH ANNUAL INSPECTION Inspect required in daily and 30 day inspections Inspect all welded connections Inspect all pivot and clamping connections such as the suspension pivots and shock mounts DO NOT PAINT THIS STICKER RIDEWELL SUSPENSION TORQUE CHART _ BOLT SIZE LUBRICATED THREADS 1 1 2 1 100 FT LB 1 490 1 1 4 1 000 FT LB 1 020 N m 1 1 8 500 FT LB 680 f 1 GRADE 5 360 FT LB 490 1 GRADE8 460 FT LB 625 N m 7 8 350 LB 475 3 4 GRADE 5 160 FT LB 220 3 4 GRADE 8 190 FT LB 260 N m 5 8 100 FT LB 135 3 4 50 70 1 2 25 FT LB 35 After suspension has been in operation for approximately 6 000 miles 10 000 KLMS all fasteners must be re tightened to specified torque Repeat every 50 000 miles 80 000 KLMS DO NOT OVER TORQUE 990301 2 AP
47. ashers and locknuts that attach the ride height control valve to the frame mounting bracket 8 Remove the ride height control valve See Figure 7 13 Figure 7 13 Frame Height Control Valve Height Control Valve Link Assembly ASSEMBLY 1 Install the ride height control valve to the frame mounting bracket by attaching the 5 16 washers and locknuts Tighten to 3 80 90 inch pounds torque 2 Install brass fittings into height control valve using Teflon thread seal 3 Install air lines to ride height control valve 4 Install the height control valve link assembly to the ride height control valve arm by attaching the 5 16 washer and locknut Tighten to A 80 90 inch pounds torque 5 Remove jack stands and lower frame of vehicle 6 Airup system 7 Verify proper ride height adjustment see ride height adjustment Preventive Maintenance Section of this publication 17730 246 25 1 0 APPENDIX BLUE BIRD 314 0 BLUE BIRD APA SERVICE MANUAL COMFORT AIR TRANSVERSE ROD DISASSEMBLY 1 Remove the 5 8 bolts washers and locknuts that connect the transverse torque rod to the frame bracket and axle 2 Remove transverse torque rod ASSEMBLY NOTE Hendrickson requires the use of Grade 8 bolts and Grade C locknuts be used for all rod attachments Install transverse torque rod by attaching the 5 8 bolts washers and locknuts to the frame bracket and axle See manufacturers for torque
48. at provided by the vehicle manufacturer before conducting any maintenance service or repair EXPLANATION OF SIGNAL WORDS Hazard Signal Words Danger Warning Caution appear in various locations throughout this publication Information accented by one of these signal words must be observed to help minimize the risk of personal injury to service personnel or possibility of improper service methods which may damage the vehicle or render it unsafe Additional Notes or Service Hints are utilized to emphasize areas of procedural importance and provide sug gestions for ease of repair The following definitions indicate the use of these signal words as they appear throughout the publication 1 APPENDIX 0 BLUE BIRD 0 BLUE BIRD SERVICE MANUAL COMFORT AIR H INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO MACHINE OR MINOR PERSONAL INJURY NOTE An operating procedure practice condition etc which is essential to emphasize SERVICE HINT APPENDIX A helpful suggestion which will make the servicing being performed a little easier and or faster WARNINGS FASTENERS LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE LOSS OF VEHICLE CONTR
49. ct The informa tion in this publication contains parts lists safety information product specifications features proper maintenance and rebuild instructions for the COMFORT AIR Suspension Hendrickson reserves the right to make changes and improvements to its products and publications at any time Contact Hendrickson Tech Services at 630 910 2800 for information on the latest version of this manual Product Description 1 APPENDIX The COMFORT AIR rear suspension system based on Hendrickson s proven HAS technology is designed for the needs of buses motor homes and ambulances The new system combines superior ride and handling with enhanced equipment protection m Frame Hanger Bracket Wide footprint distributes load over a larger area for reduced frame stress m QUIK ALIGN Fast and easy alignment without shims see Figure2 1 m Main Support Member Extended length generates lower spring rate for optimized roll stiffness providing a more comfortable and compliant ride It also provides neutral roll steer for better handling m Shock Absorbers Shock absorbers are tuned for optimum damping characteristics fo provide maximum driving comfort m Air Springs Adjusts to changing load conditions to deliver superior ride quality m ULTRA ROD Lightweight and durable torque rod the ULTRA ROD is an integral component of the COMFORT AIR suspension that enhances handling during cornering and helps maintain la
50. e rear spring suspension is accomplished in the reverse order of the removal instructions above and according to the torque values below Always use new hardware when installing high torque suspen sion applications Torque hexnuts at the rear hanger to 100 125 ft Ib 135 169 Nm 284 Use new cotter pins at the rebound pins Bend each leg of the cotter pin at least 45 to secure it Torque hexnuts 30 to 75 100 ft Ib 102 135 Nm Torque hexnuts 32 to 300 350 ft Ib 407 474 Nm Torque hexnuts 40 to 106 112 ft Ib 144 151 Nm Install brake lines in accordance with instructions the Brakes Section of this service manual Install speed sensors in accordance with instructions in the Brakes Section of this manual Install wheels in accordance with instructions in the Front Suspension Section of this service manual VITAMIN Always use new hardware high torque applications Never re use hardware in suspension applications 1 Position the axle saddle block over the location pin on the axle housing 2 Position the spring assembly in the saddle block 3 Position the U bolt seat on the top of the spring 4 Position a new U bolt at the forward groove in the U bolt seat 5 Position a new U bolt at the rearward groove of the U bolt seat 6 Position the lower U bolt bracket over the ends of the U bolts 7 Install the spherical washers on the U bolt Flat wash
51. eaction with the bushing such as deterio ration of the rubber Press in the new bushings Support the torque rod end on the receiving tool with the end tube of torque rod centered on the receiving tool The straddle mount bar pin bush ings must have the mounting flats positioned at zero degrees to shank of the torque rod Press directly on the straddle mount bar pin of bushing The rubber bushings of the bar pin must be centered within the torque rod end tubes 26 17730 246 REAR AXLE amp SUSPENSION APPENDIXES E H COMFORT AIR 7 When pressing in the new bushings overshoot the desired final position by approxi mately 3 16 see Figure 7 16 8 Press the bushing again from opposite side to center the bar pin within the torque rod end see Figure 7 17 9 Wipe off excess lubricant Allow the lubricant four hours fo dissipate before operating vehicle 10 Replace torque rod assembly as detailed in the Component Replacement section Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 e 17730 246 27 1 0 APPENDIX BLUE BIRD e SERVICE MANUAL COMFORT AIR H SECTION 8 COMFORT AIR Plumbing Diagram 316 Delivery to Airspring BR n S TC Dump port Intake Pressure protection X Continuous normally open Press switch on dash plug Exhaus port
52. ebound pins front and rear 25 Install flat washers on bolts 26 Install hexnuts 27 Make standard check for dog tracking adjustment 0 BLUE BIRD SERVICE MANUAL 28 When laser mark is within 1 4 inch of center adjusted with shims in step 23 above torque hexnuts to 100 125 ft Ib 135 169 Nm 29 Using a crisscross pattern torque hexnuts to 300 350 ft Ib 407 474 Nm in 10 ft 13 Nm increments 30 Install flat washer on bolt 286 31 Position the top end of the shock absorber between the shock absorber brackets on the frame rails Ensure that the bolt is properly oriented with the head toward the front of the bus 32 Install bolt and washer through the hanger brackets and the top end of the shock absorber 33 Install the flat washer on bolt 34 Install hexnut on bolt Torque to 75 100 ft Ib 102 135 Nm 35 Position the lower end of the shock absorber at the lower shock mount En sure the bolt is properly oriented with the head toward the rear of the bus 36 Install a flat washer on bolt 37 Install bolt and flat washer through the lower end of the shock and install a flat washer on the bolt 38 Position the lower end of the shock at the lower shock mounting bracket and install the bolt and washer assembly through the lower mounting bracket 39 Install a flat washer and hexnut on bolt Torque to 75 100 ft Ib 102 135 Nm 40 Install brake lines
53. eight control or leveling valve system the springs would deflate one side only Simply deflate the other side by removing the vertical linkage rod from the valve and rotate the horizontal lever arms down to fully exhaust the springs Air Pressure amp Brake Protection Valve This air ride suspension is dependent air pressure from the vehicle supply system Air pressure must be maintained above 65 p s i before operation A brake protection valve must be installed in the air system to prevent air loss below 65 p s i and to insure safe air brake pressure in the event of air loss in the suspension system Shock Absorbers The suspension is equipped with shock absorbers to dampen dynamic frequencies The shock absorber is very important and must be maintained to insure smooth operation e APPENDIX BLUE BIRD 324 e BLUE BIRD SERVICE MANUAL OPERATIONAL INSPECTION 1 Inspect all fasteners at hanger to frame connections 2 Build and maintain vehicle air pressure to 65 p s i minimum Inspect air springs Make sure all springs inflate and do not leak Soap test if leaking is suspected Check all air connections for leaks and tighten if needed Inspect air lines They should be free of sharp edge contact to prevent premature failure Check for proper ride height If incorrect adjust per Section 7 of this manual Cross members must be installed between h
54. ely through the rubber P connector at all times 2 APPENDIX e BLUE BIRD 330 e BLUE BIRD ALL AMERICAN SERVICE MANUAL SHOCK ADJUSTMENT PROCEDURES If your suspension is equipped with Koni Adjustable Shock Absorbers and require adjustment proceed as follows NOTE Read this entire procedure before starting 1 Remove the shock absorber from the vehicle and hold it vertically with the lower eye in a vice 2 Press top of shock down while turning gently counter clockwise until you feel the cams of the adjusting nut engage in the recesses of the front valve assembly When engagement is made turn top of shock 2 half turns clockwise and stop Adjustment is complete 3 Pull top of shock up about and remove from vice 4 Re install on vehicle IMPORTANT NOTE Shock absorbers must be adjusted in pairs There is a maximum of 5 half turns clockwise adjustment on your shock absorber Do not use excessive force when making adjustments If you are having difficulty please contact your nearest Ridewell representative 2 APPENDIX REAR AXLE amp SUSPENSION APPENDIXES PARTS ILLUSTRATIONS e BLUE BIRD 25 SERVICE MANUAL 2119100221 E BOGSA 5 4 5 896 Od TIIMI mapo am wows sm evaa sow
55. ember 15 Main Support Member Assembly Pivot Bushing 17 Spring Seat Bottom Cap 19 EP nace 21 Cross ter pr 22 Wane Ba dnd oe 23 Upper Shock Absorber Frame 23 Lower Shock Absorber 24 Ride Height Control Valve 6 ee 25 Transverse ROG ack edere aca 26 Transverse Rod Bushing 26 Section 8 COMFORT AIR Plumbing Diagram 28 Section 9 Trouble Shooting Guide 29 Section 10 Tightening Torque Specifications 30 ortho Read head HENDRICKSON 1 0 APPENDIX BLUE BIRD 290 0 BLUE BIRD lt ALL AMERICAN SERVICE MANUAL COMFORT AIR SECTION 1 Introduction p H This publication is to acquaint and assist maintenance personnel in preventive mainte nance and rebuild of the COMFORT AIR suspension system NOTE SECTION 2 Use only Genuine Hendrickson parts for servicing this suspension system Most Hendrickson parts can be identified by the Hendrickson trademark It is important to read and understand the entire Technical Procedure publication prior to performing any maintenance service repair or rebuild of the produ
56. emov ing the rear disc rotor hub assembly Maintenance Maintenance of the rear axle and suspension consists of periodic general inspection checking tightness of fasteners and axle lubrication fluid level check and or replace ment Refer to the maintenance charts on the next page also included in the Specs amp Maintenance chapter for intervals and lubricant specs REAR AXLE amp SUSPENSION Rear Axle amp Suspension INTERVAL 1000 Mites whichever occurs first 8 9 2 2 9 ai 8 wn OPERATION e a 5 Rear Axle Check lubricant 269 Hypoid Gear Oil Capacity 35 pints 16 9 litres Change Lubricant Petroleum Based e For viscosity recomendation see Axle Lubricant chart below Change Lubricant Synthetic Spring Suspension Inspect visually Check rebound pins Verify that cotter pins are installed Torque spring radius fasteners Tighten locknuts to 100 125 ft lb 11 14 Nm Torque shock mounting bolts Tighten locknuts to 75 100 ft lb 9 11 Nm Torque U bolt fasteners Torque U bolts to 300 350 ft lb 34 39 Nm Air Suspension Inspect visually Check for wear damage loose or missing parts Torque upper shock mount Tighten to 50 70 ft lb 68 95 Nm Torque lower shock mount Tighten to 150 180 ft lb 203 244 Chec
57. en 1 77 nuts to 1 000 ft Ibs torque Procedure 2 For suspensions with threaded rod type adjustable torque arms only 1 Loosen cast clamp bolts on threaded torque arms 2 lower most torque arm threaded rod either clockwise or counter clockwise to lengthen shorten torque rod as required Measure new length of lower torque arm using center of mounting bolts as reference Adjust upper torque arm to match lower arm length Check alignment and repeat as necessary o m eo Tighten cast clamps on adjustable torque arm to 100 ft Ibs torque Procedure 3 For suspensions with eccentric bolt adjustment on lower torque beam and an upper threaded rod type type adjustable torque arm 1 Loosen all 1 4 eccentric bolt nut 2 Remove anti turn washer from eccentric bolt head 3 Align axle by turning eccentric bolt arrow on bolt head to the direction the axle needs to move 4 Loosen cast clamps on torque arm and adjust the upper threaded rod type torque arm approxi mately the same distance the axle has moved Check alignment and repeat as necessary After alignment is achieved install anti turn washer to eccentric bolt head a 6 Tighten 1 nut to 1 000 ft Ibs torque 7 Tighten cast clamps on adjustable torque arm to 100 ft 165 torque e APPENDIX BLUE BIRD 328 e BLUE BIRD ALL AMERICAN SERVICE MANUAL BUSHING REPLACEMENT PROCEDURES Procedure 1 Repl
58. ers must be hardened 8 Install the flat washers on the U bolt 9 Loosely install the hexnuts on U bolt 10 Install the spherical washers on U bolt at 2 places 0 BLUE BIRD REAR AXLE amp SUSPENSION 11 Install the stabilizer bar bracket if so equipped on U bolt 12 Install the lower shock absorber bracket on U bolt 13 Install flat washers on U bolt 14 Loosely snugly enough to prevent movement install hexnuts on U bolt TID To prevent distortion of the U bolts tighten hexnuts in a crisscross 2 8 5 pattern after initial contact snug 15 Temporarily install the inner wheels and position the axle assembly in the hanger brackets to ensure the springs are located properly Then remove the wheels 16 Position the rearward spring end in the rearward spring bracket 17 Install the rebound pin in the aft mounting bracket 18 Position the forward spring end in the forward mounting bracket 19 Locate the spring radius leaf pin at the forward side of the bracket 20 Install the rebound pin 21 Install new bolts through the spring end assembly and the forward spring mounting bracket lugs 22 Install new cotter pins Ensure that any shim s removed during disassembly are replaced in the proper positions Ensure that the bolts are oriented in the proper direc tion 23 Install shims 16 between the head of the bolts and the lugs on the mount ing bracket 24 Install new cotter pins at r
59. ever prema ture bushing wear can occur and will require replacement The main support member assembly pivot bushing should be replaced if it exhibits excessive fore aft movement or the vehicle is experiencing excessive tire wear on the rear axle For instructions on bushing replacement see the Component Replacement section of this publication U BOLT LOCKNUTS Retighten to proper torque as shown in Figure 5 1 after the first 1 000 miles of service on new vehicle or vehicle with serviced axle attachment assembly and then at regular inter vals as experience dictates DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to AJ 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to A 285 305 foot pounds torque Figure 5 1 6 0 6 H C2 5 778 Locknut JL Tightening Torque 400 450 ft Ibs ine or 3 4 Locknut Axle Bottom Cap Tightening Torque 285 305 ft Ibs RIDE HEIGHT SETTING Proper ride height is essential for maximum ride quality and performance Proper adjust ment of the ride height control valve is described below If the valve or linkage assembly becomes damaged they will require replacement See the Component Replacement Section in this publication 1 Place vehicle on level floor 2 Freeand center a
60. flat washers and bolt from each end of the axle 10 To drop the axle remove hex nuts flat washer and spherical washer from 4 places and lower the axle wheels assembly If working on only one end of the axle it is possible to do so by dropping only one side However care must be taken to avoid twisting the sus pension on the other side Lower the end being worked on only enough to clear the location pins on the springs and axle This will make location of compo nents easier during reassembly 11 To drop the springs skip step 12 and remove and discard the cotter pin from the rebound pin at the forward spring hanger 12 Remove the rebound pin 13 Remove and discard the cotter pin from the rebound pin at the rearward spring hanger 00919 Carefully note the position of any shims in the next step During reassembly they must be replaced in the same positions 14 Remove hexnuts 26 flat washers 25 shims 16 and bolt 24 from 2 places at the rearmost spring hanger 11 15 Loosely install the inner wheels onto axle ends 16 Carefully lower the suspension axle wheels assembly and roll it out from un der the vehicle VITAMIN f any frame members are to be removed or any suspension hangers they must be replaced in accordance with instructions in the Frame section of this service manual 283 0 BLUE BIRD SERVICE MANUAL Rear Spring amp Axle Installation Installation of th
61. impor tant that the tightening torque of the nuts be checked during preventive maintenance serv ice Follow the vehicle manufacturer s specifications for tightening torque values All torque rods can be inspected for looseness or torn or shredded rubber With brakes applied slowly rock an empty vehicle with power while a mechanic visually checks the action at both ends Or with the vehicle shut down a lever check can be made with a long pry bar placed under each rod end and pressure applied Rod ends can be renewed by pressing out the worn end and installing a replacement bush ing A two piece rod is also available to cut and weld the desired length see Hendrickson publication no 59310 001 NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts be used for all rod attachments SHOCK ABSORBER INSPECTION Hendrickson uses a long life premium shock absorber on all COMFORT AIR suspensions When the shock absorber replacement is necessary Hendrickson recommends that the shock absorbers be replaced with identical Hendrickson Genuine parts for servicing Failure to do so will affect the suspension performance and will void the warranty Inspection of the shock absorber can be performed by doing a heat test and a visual inspection For instructions on shock absorber replacement see the Component Replacement Section of this publication It is not necessary to replace shock absorbers in pairs if one
62. in accordance with instructions in the Brakes Section of this service manual 41 Install speed sensors in accordance with instructions in the Brakes Section of this service manual 42 Install wheels in accordance with instructions in the Brakes Section of this service manual Air Rear Suspension For servicing the Hendrickson Comfort Air rear suspension see Appendix 1 of this chapter Hendrickson publication number 17730 246 0 BLUE BIRD REAR AXLE amp SUSPENSION 287 0 BLUE BIRD 288 Q E MERICAN se vice ALL REAR AXLE amp SUSPENSION APPENDIXES H TECHNICAL PROCEDURE COMFORT AIR SUBJECT Service Instructions LIT NO 17730 246 DATE December 2001 REVISION A TABLE OF CONTENTS Section 1 2 Section 2 Product Description 2 Section 3 Important Safety 3 Section 4 CR eg 6 Section 5 Preventive Maintenance Main Support Member Bushings 8 BOlE LOGKNUES desee edes ont cb 8 Ride Height essen ec IURE 8 Transverse ROUS su aed a tare afd 10 SHOCK ADSOMDGh take ob eere de per den ee 10 Section 6 Alignment rrr REUS 12 Section 7 Component Replacement erac reed ere Pa e eee pup 14 Main Support M
63. k ride height Shock length eye to eye 22 68 25 576 6 mm Check U bolts 7 8 14 UNF 28 Tighten to 400 450 ft lb 542 610 Check U bolts 3 4 16 UNF 28 Tighten to 260 320 ft lb 353 434 Nm Torque lower shock mount to spring Tighten to 260 320 ft lb 353 434 Torque air spring anchor bolts Tighten to 20 30 ft lb 27 41 Nm Torque quick align bolts Tighten to 525 575 ft lb 712 800 Nm Torque lever linkage locknut Tighten to 100 150 in Ibs 11 17 Torque Leveling valve mount bolt Tighten to 60 85 in Ibs 7 10 Rear Axle Viscosity Temperature Chart Meritor Lubricant Specification Description Cross Reference Minimum Outside Temperature Maximum Outside Temperature 0 76 Hypoid Gear Oil GL 5 S A E 85W 140 10 F 12 2 C 0 76 Hypoid Gear Oil GL 5 S A E 80W 140 15 26 1 C i 0 76 D Hypoid Gear Oil GL 5 S A E 80W 90 15 26 1 C Hypoid Gear Oil GL 5 S A E 75W 90 40 F 40 C 0 76 J Hypoid Gear Oil GL 5 S A E 75W 40 F 40 C 35 F 1 6 C 0 76 L Hypoid Gear Oil GL 5 S A E 75W 140 40 F 40 C d No upper limit on these temperatures However axle sump temperature must never exceed 250 F 121 C 0 SERVICE MANUAL 3 84 Forward Engine
64. l JI UJ 5 Using C clamps securely clamp six foot piece of STRAIGHT bar stock or angle iron across the lower frame flange as shown in Figure 6 1 Select a location as far forward of the drive axle as possible where components will not interfere 6 Accurately square straight edge to frame using a carpenter s square 12 17730 246 H WARNING REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR 7 Using a measuring tape measure from straight edge to forward face of drive axle arm at the centerline of the spring seat on both sides of vehicle as shown in Figure 6 1 and If both sides measure within 1 8 of being equal alignment of drive axle is acceptable If A and B differ by more than 1 8 the following procedure must be fol lowed m Loosen the left pivot bolt locknut to snug 100 foot pounds See Figure 6 2 This will hold the eccentric flanged washer in place against the hanger face and within the adjustment guide but loose enough to permit the eccentric flanged washer to rotate freely m Using an alignment fool or 1 2 square drive breaker bar rotate the left eccentric align ment collar to align axle Clockwise rotation moves axle forward counter clockwise rotation moves axle rearward A 90 rotation of the QUIK ALIGN collar will move axle fore and V2 from center DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FA
65. ll suspension joints by slowly moving the vehicle back and forth with out applying the brakes When coming to a complete stop make sure the parking brakes are released Chock front wheels of vehicle Loosen the clamp on the adjustable extension rod Remove the locknut and washer at height control valve leveling arm Verify that air system is at full operating pressure Exhaust the air in the air springs to relax the suspension Then refill the air springs to proper ride height oa Fr 8 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR Dimension A The ride height can be measured at the centerline of the main support member assem bly as shown in Figure 5 2 The ride height is 47 8 1 4 at the A dimension shown Dimension B This option measure the normal running length of the shock absorber will measure the ride height on the shock from center of eye to center of eye see dimension B in Figure 5 2 The specific running length of the shock absorber varies per specific OEM applications as shown in the matrix DIMENSION A DIMENSION B RIDE HEIGHT SHOCK ABSORBER LENGTH OEM AND MODEL FROM BOTTOM OF FRAME TO BOTTOM AT RIDE HEIGHT OF MAIN SUPPORT MEMBER WITH A TOLERANCE OF 1 4 BLUE BIRD RE QBRE 47 8 22 75 BLUE BIRD TCFE CSFE 47 8 22 75 BLUE BIRD TSFE CIFE 4 7 8 23 BLUE BIR
66. lve Kit Includes 1 17 64272 000 Spring Clip Sleeve 4 Key Nos 48 50 18 37042 002 7he 14UNC Bolt 2 48 Height Control Valve 1 22962 027 7 16 Washer Not Shown 49 22962 028 1 4 Hardened Washer 2 19 17700 007 7 16 14UNC Nut 2 50 49983 000 1 4 20UNC Locknut 2 20 Clip Bolt Spacer 2 Control Valve Lower Link Bracket Kit 21 56805 000 Top Pad 2 Includes Key Nos 51 54 57724 000 Top Pad 15 000 Ib capacity 2 57430 000 All Except Rear Engine U Bolt Kit 57430 003 Rear Engine Only 48718 7 8 Specify Length Includes Key 51 56789 000 Control Valve Link Bracket 5 22 23 24 25 58367 000 Control Valve Link Bracket Rear Engine 48718 104 3 4 15 000 Ib capacity Includes 52 56935 002 1 4 20UNC 1 00 Bolt 2 5 22 24 25 53 22962 028 1 4 Hardened Washer 4 22 47417 7 8 14UNF U Bolt Specify Length 4 54 49983 000 1 4 20UNC Locknut 2 49684 014 3 4 26UNF U Bolt 12 5 58994 Height Control Valve Link Assy Specify 1 15 000 Ib Capacity 4 Length Includes Key Nos 55 61 23 48574 000 Spherical Washer 8 55 Extension Rod 1 24 22962 002 7 8 Hardened Flat Washer 8 56 5 16 18UNC Jam Nut 2 22962 001 3 4 Hardened Flat Washer 57 gt 5 16 18UNC Locknut 2 15 000 Ib Capacity 8 58 5 16 Hardened Washer 2 25 50765 000 7 8 14UNF U Bolt Locknut 8 59 5 16 18UNC Stud 2 49685 000 3 4 16UNF U Bolt Locknut 60 Valve Arm Clamp 15 000 Ib Capacity 8 61 Adjustable Valve Arm Joint 26 48531 014 Spacer 1 5 As Required 2
67. n support member assembly to the frame hanger Verify that the nose of each QUIK ALION collar is installed into the pivot bushing sleeve and the flanged side is flat against the hanger face within the alignment guides NOTE The eccentric collar is located on the outside frame on the left side of chassis with the concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger 14 17730 246 1 BLUE BIRD APPENDIX 0 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR 3 Snug the left pivot bolt to 3 100 foot pounds torque Tighten the right pivot bolt to A 525 575 foot pounds torque 4 Remove jack stands and lower frame of vehicle 5 Air up the system 6 Align the rear axle see alignment Preventive Maintenance Section of this publication MAIN SUPPORT MEMBER ASSEMBLY The Main Support Member Assembly should function satisfactorily during normal vehicle operation Replacement is only required when the Main Support Member Assembly has been damaged or worn Figure 7 2 Hanger Eccentric Collar Secondary Spring Clip Sleeve Main Support Member Spring Seat Lower Shock Bracket Axle Bottom Cap 7 8 Locknut OR Locknut Tightening Torque Tightening Torque 34 10UNC Locknuts 400 450 ft Ibs 285 305 ff Ibs Cross Tightening Torque Channel 260 320 ft Ibs DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of
68. nect the cross channel to the main support member assemblies to R 260 320 foot pounds torque Figure 7 10 5 Tighten the U bolt locknuts evenly and tighten to the proper torque in the proper sequence see Figure 7 10 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to R 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to 3 285 305 foot pounds torque Remove jack stands and lower the frame of vehicle 7 Install height control valve link on control valve arm Tighten 5 16 lockwasher and nut to A 80 90 inch pounds torque Air up the system AXLE BOTTOM CAP DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 20 17730 246 1 BLUE BIRD APPENDIX 0 H WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR 17 Remove the U bolt locknuts and washers 18 Remove axle bottom cap AXLE BOTTOM CAP ASSEMBLY 1 Install axle bottom cap on axle in proper direction 2 Assemble U bolts washers and locknuts 3 Tighten the U bolt locknuts evenly and tighten to the proper torq
69. ning dust cap to the left counterclockwise until it is felt that cams of internal adjusting nut en gages in the recesses of the internal foot valve While engaged turning the dust cap fully counterclockwise puts the shock at its minimum dampening setting Skip to step 3 if no damping increase is required 2 Keeping shock absorber collapsed turn dust cap to the right clockwise until a stop is felt Stop turning and do not use any more force This Is the maxi mum dampening setting To reduce dampening turn counterclockwise 3 Pull shock absorber out vertically without turning for at least 3 8 to dis engage the adjusting mechanism The dust cap may now be turned freely Shock absorber can then be re fitted to the vehicle When reinstalling tight en shock absorber upper amp lower nut item 23 until a dimensionof 1 75 between washers is attained as shown 4 Make certain both left and right shocks are at equal settings Repeat steps 1 3 as required 0 BLUE BIRD 282 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL Rear Spring amp Axle Removal Never work under a bus supported solely by hydraulic jacks Al ways use jack stands or blocks to secure the vehicle Ensure that the floor is firm enough to support the weight of the vehicle on the reduced footprint of the lifting holding device 1 Raise the vehicle observing all appropriate safety precautions for working under the bus Park the bus on
70. ot have outer metals 6 Clean and inspect the of the main support member eye ASSEMBLY 1 Insert the spring eye clip if equipped into the gap of the main support member eye see note above If spring eye clip is damaged or not present it is necessary to cut a strip of Scotch 890 black fiber tape or heavy bodied duct tape 1 x long 2 Feed the tape into the spring eye adhesive side facing gap in the eye Center the tape equally around each end 3 Pull the tape tight and wrap it around the outside of the eye Additional tape may be required depending on gap size Ensure that the gap is completely covered See Figure 7 7 Figure 7 7 REINFORCED TAPE LAID INSIDE THE SPRING EYE TO COVER THE SHARP SCARFED EDGE GAP 4 Lubricate inner diameter of steel spring bore and the new rubber bushing with a vegetable base oil cooking oil DO NOT use petroleum or soap base lubricant it can cause an adverse reaction with the bushing material such as deterioration 5 Support the main support member on the receiving tool with the end hub centered on the tool Be sure the main support member is squarely supported on the press bed 18 17730 246 H CAUTION WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR Figure 7 8 6 Locate the push out tool on inner sleeve and press in the new bushing Bushings must be centered within the spring eye When pressing in the new
71. rque to 300 310 ft lb To prevent distortion of u bolts tighten nuts simutaneously w 4 spindle equipment or alternately in diagonal pattern w manual equipment 12 Install frame mounted shock brakets items 1 amp 2 as shown 13 Install inner dual tire and wheel assemblies temporarily for movement of spring and axle assembly only if req d 14 Assemble spring and axle assembly to chassis 0 BLUE BIRD 272 0 BLUE BIRD ALL AMERICAN SERVICE MANUAL 15 16 17 18 19 20 When spring assembly makes contact with the rear spring hanger bracket item 10 install rebound pin item 15 Install cotter pin thru rebound pin as shown both sides of casting when spring assembly makes contact w frt spring hanger brkt item 11 install rebound pin item 15 Install cotter pin thru cotter pin hole in casting and rebound pin as shown Attach spring radius leaf pin to front side of hanger item 11 using fasteners as shown Torque 5 8 fastener to 100 125 ft lb Install shocks item 12 as shown If axle housing interferes with installing bolt reverse bolt direction Torque shock mounting 3 4 fasteners to 75 100 ft lb If axle dog track adjustment is required follow procedure below 18 1 using beeline or other suitable equipment make standard check for drive axle dog tracking If laser mark is within 1 4 of center no further alignment is required Skip to step c 18 2 laser mark is greater than 1
72. shock absorber requires replacement 1 APPENDIX 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR HEAT TEST 1 Drive the vehicle at moderate speeds for fifteen minutes Figure 5 5 WARNING DO NOT GRAB THE SHOCK AS IT COULD POSSIBLY CAUSE PERSONAL INJURY DUE TO HOT SURFACE OF SHOCK BODY 2 Lightly touch the shock body carefully below the dust cover see Figure 5 5 3 Touch the frame to get an ambient reference A warm shock absorber is acceptable a cold shock absorber should be replaced SHOCK ABSORBER VISUAL INSPECTION PROCEDURE Inspect the shock absorbers fully extended Shock absorbers see Figure 5 6 will need to be replaced for any of the following m Damaged upper or lower mount m Damaged upper or lower bushing m Damaged dust cover and or shock body m Bentor dented shock m Leaking shock when streams of fluid travel down the side of the shock particularly from the upper seal The suspension is equipped with a premium seal on the shock however this seal will allow for misting to appear on the shock body misting is not a leak and is considered acceptable m Shock is damaged internally jammed in the collapsed position It can also be deter mined by removing the shock shake and listen to the sound of metal parts rattling inside the shock body Figure 5 6 Welded Shock Mount O Leaking may occur from this area Shock Body Lower Welded
73. specifications 2 Verify lateral axle alignment and correct with drop in shims between the torque rod bar 1 APPENDIX pin and the frame or axle bracket depending on the direction of alignment TRANSVERSE ROD BUSHING Remove transverse torque rods as detailed in the previous section DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE THE BUSHINGS FROM THE TORQUE ROD THE USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE HEAT CAN CHANGE THE MATERIAL PROPERTIES COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE You will need 1 vertical press with a capacity of at least 10 tons A receiving tool 5 long 2 inner diameter by wall steel tubing Support the torque rod end on the receiving tool with the end tube of torque rod centered on tool Be sure the torque rod is squarely supported on press bed Push directly on the bushing straddle mount bar pin until top of the bushing is level to the top of torque rod end tube Press until the bushing clears the torque rod end tube Clean and inspect the inner diameter of the torque rod ends removing any nicks with an emery cloth or a rotary sander See Figure 7 14 Lubricate the inner diameter of the torque rod ends and the new rubber bushings with a vegetable base oil cooking oil see Figure 7 15 DO NOT use a petroleum or soap base lubricant it can cause and adverse r
74. t member assembly Replace main support member assembly Air spring s not inflated Check air supply to air spring repair as necessary Vehicle leans Main support member assembly broken Replace main support member assembly Axle connection not torqued correctly Perform U bolt retorque procedure See Torque Specification Section of this publication Worn pivot bushing Replace pivot bushing Air spring s not inflated Check air supply to air spring repair as necessary Suspension is noisy Loose attachment Replace QUIK ALIGN connection and check suspension alignment Check frame hanger for wear around QUIK ALIGN plates amp replace if necessary Loose bolts Perform U bolt retorque procedure See Torque Specification Section of this publication Worn main support eye spacers Replace worn main support eye spacers pucks Worn main support clip spacers Replace worn main support clip spacers sleeves Irregular tire wear Worn pivot bushing Replace pivot bushing Loose QUIK ALIGN attachment Replace QUIK ALIGN connection and check suspension alignment Check frame hanger for wear around QUIK ALIGN plates amp replace if necessary 17730 246 29 1 APPENDIX 0 BLUE BIRD SERVICE MANUAL COMFORT AIR H SECTION 10 Torque Specifications 318
75. tach the upper frame bracket per vehicle manufacturer specifications 5 Remove frame bracket ASSEMBLY 1 Install the upper shock absorber frame bracket by attaching the fasteners per vehicle manufacturer specifications 17730 246 23 1 0 APPENDIX BLUE BIRD 312 0 BLUE BIRD APA SERVICE MANUAL COMFORT AIR 1 APPENDIX p H Install shock absorber to upper frame bracket stud by attaching washers and lock nut Washers must be installed on each side of shock absorber bushing Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut Tighten Y locknut to 3 50 70 foot pounds torque and locknut to RI 160 180 foot pounds torque LOWER SHOCK ABSORBER BRACKET DISASSEMBLY 1 2 Chock wheels of axle Raise frame of vehicle to remove load from suspension VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the locknut and washers that connect the shock absorber to the upper frame bracket 5 Remove the 34 bolt washers and locknut that connect the shock absorber to the lower bracket See Figure 7 12 6 Remove the shock absorber 7 Remove the 34 bolts washers and locknuts that connect the cross channel and lower shock absorber bracket to the m
76. teral axle position m Height Control Valve Maintains precise ride height control through changing road surfaces load and driving conditions 2 17730 246 H SECTION 3 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR COMFORT AIR is available in suspension capacities up to 23 000 pounds and in ride heights of 8 5 and 10 5 The suspension weighs 487 pounds and includes the frame hanger brackets main support member assembly axle clamp group air springs shock absorbers cross channel upper and lower shock brackets ULTRA ROD transverse torque rod and frame bracket and height control system Figure 2 1 Frame Hanger Bracket Member IMPORTANT SAFETY NOTICE 17730 246 Proper maintenance service and repair is important the reliable operation of the suspen sion The procedures recommended by Hendrickson and described in this technical publi cation are methods of performing such maintenance service and repair The warnings and cautions should be read carefully to help prevent personal injury and to assure that proper methods are used Improper servicing may damage the vehicle cause personal injury render it unsafe in operation or void manufacturer s warranty Failure to follow the safety precautions in this manual can result in personal injury and or property damage Carefully read and understand all safety related information within this publication on all decals and th
77. ther shock length or air spring height Ridewell Ride Height Frame to Axle 8 50 0 25 Shock length Ride Height Hendrickson 22 68 0 25 eye to eye Ridewell 17 53 0 25 eye to eye 280 Air Spring Ride Height 8 0 0 25 Ride Height Adjustment Air Suspension 1 Vehicle to be on level ground with 70 120 psi system air pressure maintained Left and right rear height control valves to be adjusted independently 2 Remove vertical rod from first valve horizontal arm amp from lower stud Rotate horizontal lever arm down to fully exhaust air springs 3 Rotate horizontal lever up filling air springs until affected side of vehicle is at specified ride height Bring arm to neutral horizontal position when proper height is reached 4 Place centering pins in valve to hold arm horizontal Insert vertical link into upper connector sliding up or down until lower grommet can be pushed onto lower mounting stud Tighten hose clamp on upper connector and re move centering pins from valve 5 Remove vertical link lower grommet from mounting stud and rotate horizon tal link down to exhaust air 6 Reinstall grommet on mounting stud and recheck ride height 7 Ifadjustments are necessary loosen hose clamp slide connector or down as required Tighten clamp and repeat steps 5 amp 6 until ride height measure ment is within specifications 8 Repeat steps 2 7 for 2nd valve Drive Axle Alignment Ridewell Air Suspension
78. ue in the proper sequence see Figure 7 10 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to 3 285 305 foot pounds torque 4 Remove jack stands and lower the frame of vehicle 5 Air up the system AIR SPRING DISASSEMBLY Figure 7 11 Air Spring Frame Hanger 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from Air Spring VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE Suspension Lower Shock Bracket 34 10UNC Locknuts 3 Verify air is removed from the system Cross Tightening Torque Channel 260 320 1 Ibs 4 Remove the locknut and washer that connect air spring to the cross channel See Figure 7 11 5 Remove air line from air spring 6 Remove brass fittings from air spring 7 Remove the locknut and washer that connect air spring to the upper air spring hanger 8 Remove air spring ASSEMBLY 1 Install air spring in upper air spring hanger by inserting stud into hole and attach the Ya washer and locknut 2 Install air spring in spring seat by inserting stud into hole and attach the washer and locknut 21 1 APPENDIX 309 0 BLUE BIRD APA

ReaR axle & SuSpenSiOn - Central States Bus Sales, Inc.

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ReaR axle &amp; SuSpenSiOn - Central States Bus Sales, Inc.

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ReaR axle & SuSpenSiOn - Central States Bus Sales, Inc.