Neway IFS Series Maintenance Manual
Contents
1. MAINTENANCE GO THE DISTANCE MAN UAL ZD NEWAY IFS Series Independent Front Air Ride Suspension Maintenance Manual XL AK397 01 Holland Neway Technical Customer Service Tel 1 800 237 8932 Table of Contents Introduction 2 Maintenance Schedule 3 serial Number Tag Information 4 Vehicle Towing Information 5 Torque Specifications 6 7 Pre Operational Inspection 8 Control Arm Bushing 8 Tie ROQ ENOS isi dos icet erri dos on non von 3 9 Automatic Slack Adjusters 9 Air Spring Adjustment 10 Height Control Valve Adjustment 10 Adjusting Suspension Ride Height 11 Type CR and IR Height Control Valves 11 12 Lubrication 13 GONG CIP y 13 Greasing Knuckle Post Assembly 13 Didke acaseuncetustueeetoensosen ae ERR 14 Wheel Bearing and Hub Caps 14 Introduction You must read and understand all of the safety procedures presented in this manual before starting any work on the IFS suspension Proper tools must be used to perform the mainte nance and repair procedures described in this manual Many of these procedures require special tools Failure to use the proper equipment could result in personal injury and or damage to the suspension Safety glasses must be worn at all tim2. NOTE The specified grease is lithium based NLGI Grade 2 IMPORTANT While injecting grease always maintain visual sight of O rings At first sign of O ring movement stop pumping grease Slight movement indicates a full grease cavity IMPORTANT DO NOT over pump grease into grease fittings The grease gun type must not exceed 250 psi max If a high pressure grease gun is used it could cause an O ring to extrude out of the groove and degrade its function This is usually indicated by a large amount of grease extruding from the O ring joints and the O rings being visually distorted or damaged Using a proper grease gun 250 psi max pump grease into grease fitting until slight O ring movement has occurred 2 Look to ensure O rings are not distorted or damaged a If distorted or damaged replace rubber O ring seals b If not distorted or damaged knuckle post assembly is properly lubed 3 Repeat for both upper amp lower fittings on each knuckle post assembly IFS Series Suspension 13 Lubrication continued Grease Fittings Tie Rods Ends NOTE Before servicing review lubricant specifications and interval requirements Table 4 1 Ensure grease gun is filled with proper lube 2 Apply lubricant to grease fittings until new lubricant discharges from the dust boot Fig 16 Figure 16 Lubricate Grease Fittings i m mu Ex W i l Tie Rod Grease Fittings 4 total on Tie Rods
3. and remove to reduce camber Fig 24 6 Tighten bolts to 150 200 ft lbs See Torque Specs on pages 6 amp 7 7 Remove safety stands and lower vehicle Make sure the suspension is at the proper ride height refer to manufacturers ride specification 8 Remeasure the camber and readjust as needed Adjusting the Tire Toe In IMPORTANT Nearly all tire wear is caused by incorrect toe in settings Holland Neway does not recommend altering components to adjust the suspension toe in Toe in must be set by adjusting the tie rod lengths only AA WARNING Adjusting the ride height or altering com ponents to adjust the tire toe in is strictly prohibited Alteration of components could result in loss of vehicle control NOTE Toe in is the measurement of the distance between the front and the rear of the two front tires When the front distance 1s less than the rear distance the wheels are toed in Toe in is designed into the suspension to stop the tendency of the tires to toe out when the vehicle is driven straight ahead IFS Series Suspension 19 Checking and Adjusting continued Tie Rod Length Toe in Specifications 1 32 1 32 1 Use a professional alignment system to deter mine if toe in adjustment is needed If adjust ment is needed follow Steps 2 through 6 2 Measure the length of both tie rods Fig 25 If the lengths are not within 1 8 of each other the tie rods must be adjusted Tie rods are
4. properly adjusted if found to be within the 1 8 measurement 3 Block rear wheels 4 Raise front end of suspension and support with safety stands 5 Loosen tie rod clamps bolts and adjust tie rod length as needed 6 Re tighten tie rod clamp bolts to torque specs listed on page 6 7 Lower vehicle and remeasure Fig 25 Repeat procedures as necessary PARTS REPLACEMENT AA WARNING Altering or attempting to repair or modify a component can adversely effect the suspen sion strength and performance and could result in the loss of vehicle control IMPORTANT Repair or reconditioning of suspension components is prohibited Most parts are heat treated and tempered and can not be welded bent heated or repaired in any way without reducing the strength or the life of the component thus voiding the warranty Genuine component replacement only is allowed 20 IFS Series Suspension IMPORTANT The following repair methods and actions are NOT allowed on IFS suspension components including rod assemblies ball joints and subframe NO welding that involves the steering knuckles steering arms lower control arms tie rod assemblies hubs brakes or brake drums NO bending hot or cold of the spindle assembly steering arms upper and lower control arms and tie rod assemblies NO drilling out of the control arm and steering arm mounting holes and or the ball stud tapered holes NO spray welding of be
5. 4 Check the height control valve plumbing for air leaks using a water liquid soap solution 5 Make sure shock absorbers are mounted securely and mounting connections are not bent 6 If ride height is incorrect adjust ride height by the adjusting lock nut Fig 13 Loosen the 1 4 nut push up adjusting block to increase ride height and pull down to decrease ride height Re tighten 1 4 lock nut to 15 25 in Ibs NOTE Valve has a built in time delay feature therefore several seconds may elapse prior to air flow NOTE If proper ride height is not obtained or air springs do not inflate properly check air pressure and pressure protection valve check for proper pip ing and check Type CR height control valve Fig 13 and repeat above steps Then if not functioning properly contact Chassis Manufacturer or Holland Neway Service Department Figure 13 Type CR Height Control Valve Adjustment Intake Up Control Arm 1 4 Adjusting Lock Nut Adjusting Block gt IG a Exhaust Down 8 D WEZ 7m Exhaust Out To Air Spring In Air Supply Locating Pin Manufactured Date Code IFS Series Suspension 11 Pre Operational Inspection Continued Adjustment Procedure Type IR Valve 1 Prior to adjustment the vehicle must be in an unloaded condition and on a level floor 2 Pressurize the air system with a constant supply of air in excess of 105 P S I G 5 5 Bar All air springs should inflate an
6. Thd Inch x Length Grade Clean Dry Threads Nut Dia Thd Inch Ft Lb 1 Steering Gear Attachment 400 450 2 Knuckle Post Spindle Tapered Lock Pin q 55 60 3 Upper Control Arm Inner Sub Frame Connection 450 550 4 Knuckle Post Control Arm Connections 630 770 5 Lower Control Arm Inner Sub Frame Connection 150 200 6 Shock Absorber Connections 90 110 7 Steer Arm to Spindle Connections 1 18 12 680 740 8 Tie Rod Assembly Clamp Bolts Be M ee 50 minimum 9 Steer Arm to Tie Rod Assembly 7e 1MM J 125 135 10 Brake Chamber to Brake Bracket 130 170 11 Wheel Spindle Nut Wheel Bearing Adjustment See Wheel Bearing Adj 12 Pitman Arm Retaining Bolt TRW Gear Only 125 150 13 N S Pitman Arm Retaining Tab Lock Sheppard Gear Only 430 470 14 N S Pitman Arm to Tie Rod Assembly F18 14 9s c v amp CCCC CIOI IIO II S I I 125 135 15 N S Foundation S cam Brake Assembly to Spindle 220 260 16 N S Air Spring Upper Mounting Nut Air Inlet 30 40 17 N S Air Spring Upper Mounting Nut 30 40 18 N S Air Spring Lower Attachment Nut 30 40 19 King Pin Caps w Grease Fittings EE ERR 68 82 20 N S Steering Stop Jam Nut 90 110 21 N S Sway Bar Attachments Country Coach Models Only 40 50 22 N S Height Control Valve Bracket to Sub Frame 70 80 23 N S Height Control Valve to Bracket if applicable 20 30 24 N S Height Control Valve Linkage 5 10 Num
7. of the steering Wheel Alignment See page 3 for inspection intervals See Wheel Alignment guidelines page 18 if excessive steering effort vehicle wander or abnormal tire wear is evident e Fasteners Use a calibrated torque wrench to check that all fasteners are tightened to the torque specifications listed in Table 2 amp 3 on pages 6 amp 7 Wear and Damage Visually check suspension for broken or bent parts All worn damaged or out of spec components must be replaced A WARNING Altering or attempting to repair or modify a component can adversely effect the suspen sion strength and performance and could result in the loss of vehicle control IMPORTANT Repair or reconditioning of suspension components is prohibited Most parts are heat treated and tempered and can not be welded bent heated or repaired in any way without reducing the strength or the life of the component thus voiding the warranty Genuine component replacement only is allowed Refer to Part Replacement Instructions pages 20 25 Refer to Parts List on pages 28 31 for identification of suspension components Most parts are heat treated and tempered and cannot be welded bent heated or repaired in any way without reducing the strength or the life of the com ponent thus voiding the warranty 8 IFS Series Suspension Control Arm Bushings amp Connections The control arm bushings must be inspected for wear AWARNING Alway
8. Brake S Cam Tube and Automatic Slack Adjuster 1 Apply lubricant to the S cam tube until new lubricant discharges from the S cam bushing seal next to the automatic slack adjuster Fig 17 2 Apply lubricant to the automatic slack adjuster until new lubricant discharges from the cone clutch adjacent the adjusting hex nut Fig 18 Figure 17 Lubricate S Cam Tube F ij jJ Fr t p S cam Bushing Seal Grease Fittings one per adjuster 14 IFS Series Suspension Figure 18 Lubricate Automatic Slack Adjuster Slack Adjuster Zerk location Wheel Bearings and Hub Cap NOTE Before servicing Review lubricant specifications and interval requirements Table 4 page 13 Clean the hub cap window with mild soap and water only Aromatic solvents will impair the transparency of the window 1 Check oil level through the hub cap window If below the add level line remove the pipe plug and fill with recommended oil to the full level Fig 19 Add oil slowly since the heavy weight oil will settle slowly 2 Visually check the hub cap for external oil leaks Usually the vent plug will drip a small amount of oil Oil leaks in other places should be fixed by replacing either the hub cap seal window gasket or tightening the pipe fill plug Figure 19 Wheel Bearing Oil Level Wheel Bearings Preparation 1 To prevent vehicle movement Set the parking brake and block the drive wheels A WARNIN
9. Fig 23 Figure 23 Embossed Number Embossed number on knuckle post designates pre set caster angle gt NEWAY Checking and Adjusting Continued Camber Angle Adjustment A WARNING Adjusting the ride height or altering com ponents to adjust the suspension camber is strictly prohibited Alteration of components could result in loss of vehicle control Camber is the angle of the tire with respect to the ground Camber is positive when the distance between the top of both wheels is more than the distance at the ground NOTE A small amount of positive camber is built into the suspension because camber changes with load and chassis roll NOTE The camber of the suspension is affected by the ride height of the suspension If the ride height is set too high then the camber measurement will be more positive Table 6 Nominal Camber Values Unloaded Loaded Left 1 4 1 4 1 4 1 4 Right 1 4 1 4 1 4 1 4 Figure 24 Camber Angle Adjustment Mounting Bolt gt NEW AY 1 Set park brake and block rear tires 2 Raise front of vehicle off ground and support with safety stands 3 Support front tires with safety stands Loosen all lower control arm mounting bolts 4 at the sub frame 2 bolts per lower control arm bushing Fig 24 5 Add remove shims between bushing bar pin and subframe One 06 shim per bolt 4 places 1 of camber adjustment Add to increase camber
10. G Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury 2 Raise the vehicle until the front wheels are off the ground Then support the vehicle with safety stands 3 Remove the vent plug from the hub cap Adjustment 1 Attach a dial indicator with a magnetic base to the face of the hub wheel or brake drum If the wheel is removed the dial indicator may also be attached to the bottom of the brake drum 2 Place the tip of the dial indicator on the center of the steering knuckle spindle Then set the dial indicator on zero Fig 20 Figure 20 Wheel End Play Measurement NOTE Do not push pull at the top bottom of the tire drum or hub This will not yield a true measurement of the end play 3 Measure the end play by pushing pulling on each side of the tire drum or hub at the same time while observing the dial indicator The end play is the total travel observed If the end play is not within 001 005 inch adjust the wheel bearings per steps 4 10 Otherwise no adjust ment required Go to step 17 gt NEW AY Checking and Adjusting 4 Place a pail beneath the hub to catch the oil Rotate the hub so th
11. and could move allowing the vehicle to drop causing serious personal injury 2 Raise the vehicle front wheels off the ground and support with safety stands 3 Remove the front tires Disconnect the Height Control Valve HCV linkage from the lower bracket Fig 11 page 10 Upper Control Arm 1 Use a portable crane or jack and support the steering knuckle prior to disconnecting it from the control arm or removing the control arm with the steering knuckle attached The knuckle post assembly is heavy and unbalanced and must be supported properly A CAUTION Failure to properly support the knuckle post assembly could result in personal injury to hands or feet 2 Detach the upper control arm from the knuckle post NOTE DO NOT press on center metal core of bushing apply load to outer metal casing of the bushing 3 Remove the upper control arm mount bolts and remove the upper control arm Fig 26 4 Support the control arm properly during bushing removal and replacement Bushing hole of the control arms should be free of any burrs before replacing new bushings 5 Using a hydraulic press with a 15 ton capacity push bushing out of the control arm housing while supporting it securely 6 Using the same hydraulic press from Step 5 push new bushing back into the control arm housing while supporting it securely gt NEWUAY Part Replacement 7 Set control arm into its mount location Place the control
12. aring diameters on the spindle assembly steering arm bores and pivot tube Spray welding of tapered holes or ball studs for ball joint and tie rod ends NO milling machining of any component is not allowed The only exception is the honing of the control arm bushing bores to remove any burrs IMPORTANT DO NOT apply oil or corrosion pre ventative to the brake linings brake drums or bushings A CAUTION Vehicle air supply system must be completely exhausted dumped Failure to exhaust before servicing vehicle could result in sudden com ponent movement resulting in personal injury Upper and Lower Control Arm Bushing Replacement Inspect the control arms and mounts for damage If damage is found replace the complete control arm bushing assembly NOTE Holland Neway recommends replacing the bushings and mounting fasteners in all of the control arms at the same time CAUTION Using a cutting torch to remove the control arm bolts will permanently damage control arm bushings and could result in subframe damage gt NEW AY Preparation 1 Apply the parking brake and block the drive wheels to prevent vehicle movement A WARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components
13. arm mount bolts into subframe snug tight 8 Reconnect knuckle post to the outer end of the upper control arm 9 Reconnect the height control valve linkage to the knuckle post bracket 10 Set Suspension to proper ride height 11 Torque the upper control arm bolts to 450 550 ft Ibs See Torque Specs on pages 6 amp 7 IMPORTANT IFS suspension must be realigned after control arm bushing replacement Upper Control Arm Bolts Lower Control Arm 1 Use a portable crane or jack and support the steering knuckle prior to disconnecting it from the control arm or removing the control arm with the steering knuckle attached The knuckle post assembly is heavy and unbalanced and must be supported properly A CAUTION Failure to properly support the knuckle post assembly could result in personal injury to hands or feet 2 Detach the lower control arm from the knuckle post assembly 3 Remove the sub frame control arm assembly mounting bolts NOTE DO NOT press on center of bushing apply load to metal casing of bushing IFS Series Suspension 21 Part Replacement continuea Figure 27 Lower Control Arm Bushings Apply pressure to outer metal casing of bushing when removing or replacing 4 Using a hydraulic press with 15 ton capacity support and secure control arm and push bushing out of the control arm housing Fig 27 NOTE Be certain to apply pressure to outer metal casing of bushing when
14. at the hubcap drain plug is facing upwards Remove the drain plug from the hubcap and store it for installation later 5 Turn hub so that the drain hole faces downward and drain the oil from the hub cavity Wait for most of the oil to drain before continuing to the next step 6 Remove the hub cap hub cap bolts and gasket If not damaged the gasket can be re installed later To prevent component contamination place them in a clean container Note that solvents could damage the hub cap window CAUTION To avoid damage removing or installing the inner and outer spindle nuts DO NOT use an impact driver Use a torque wrench with the proper socket 7 Screw wheel bearing adjusting nut against the thrust washer while wheel is rotated Be sure there is sufficient clearance between brake shoe and drum so that there will be no brake drag 8 Tighten nut to 200 ft Ibs of torque while rotat ing wheel in both directions 9 Back off nut one full turn 10 Tighten nut to 50 ft Ibs of torque while rotating wheel in both directions 11 Back off nut 1 6 to 1 4 turn 12 Check adjustment making sure wheel rotates freely With a dial indicator place magnetic base on wheel and pointer on end of spindle Grasp wheel of hub and drum and with a push pull action record amount of axial movement 13 If movement is greater than 005 repeat adjust ment procedure If no movement is recorded repeat adjustment 14 If movement i
15. ber Plate Location 4 IFS Series Suspension Serial Number Tag Description The sample tag shown below will help you interpret the information on the Holland Neway Serial Tag The model number is on the first line along with the suspension capacity The second line contains the serial number and the third line has the parts list numbers Fig 2 This information will aid you when contacting the chassis manufacturer or Holland Neway Figure 2 Holland Neway Serial Number Tag Example HOLLAND NEWAY INTERNATIONAL INC MUSKEGON MICH U S A Holland 1 NEW AY MODEL NO CAPACITY LBS 14 000 LBS SERIAL NO IF 0213021 CD PARTS LIST NO 90547128 COVERED BY ONE OA MORE OF THE FOLLOWING PATENTS OTHER PATENTS PENDING 4 193 612 4 422 061 4 595 216 4 634 141 4 700 968 4 729 579 4 262 929 4 854 709 4 850 949 4 9fi 872 5 068 916 6 116 626 4 405 154 5 083 812 5 088 763 4 615 539 4 693 486 5 201 898 5 335 695 5 203 585 5 335 932 5 112 078 5 288 100 5 375 819 5 192 101 5 116 075 5 315 918 5 058 917 5 333 645 JAPAN PATENT 2038539 PART 93800269 4 726 571 4 736 958 5 393 096 5 413 374 The Parts List Number is directly related to Coach Builders IFS Bill of Material and will be most useful in determining proper replacement parts gt NEWAY Introduction Continued Vehicle Towing Information BEFORE attempting any type of towing procedures DO NOT attach tow apparatus hooks chains the OEM Coac
16. bered items are called out in Figure 4 IFS Pre Operational Torque Check list Item number plus N S equals Not Shown ndicates cotter pin installation necessary after torque attainment Torque spec s do not take into consideration the utilization of anti friction or anti seize compounds All torques listed are for tightening of the nuts unless otherwise noted Figure 5 Bolt Grade Markings amp Lock Nut Grade Markings Lock Nut Lock Nut Grade Grade B Grade C Grade 1 or 2 Grade 5 Grade 8 Identification 6 Dots 6 IFS Series Suspension gt AEWfAY Torque Specifications Table 3 Torque Chart Applications Fastener Size Brake Spider Mount 5 8 18 Hub Cap Bolt 5 16 18 Grade 5 1 1 8 16 Stud Piloted Wheel Nut M22 x 1 5 Hub Piloted Q2 NEW AY Torque Sequence IFS Series Suspension ntroduction Continued Torque Specifications FT LB Clean amp Dry 170 190 1 amp 2 20 30 1 450 500 3 Dry Threads Pre Operational Inspection Introduction IMPORTANT Safety glasses must be worn at all times when performing the procedures covered in this manual A thorough visual inspection of the suspension is necessary to ensure proper assembly and identify problem parts and loose fasteners before servicing Perform all of the following during the inspection Operation All components must be checked to assure that they move freely through the complete turning arch
17. case and remove the 7 8 attaching fasteners It is necessary to support the steering gear case with a support device due to its weight 6 Remove the steering gear case Installation 1 Install and support the steering gear case in position on the underside of the sub frame mounting plate 2 Install the 7 8 fasteners and torque to 400 450 ft lbs See Torque Specs on pages 6 amp 7 3 Connect the steering input shaft to the steering gear case input spline 4 Connect the hydraulic fluid supply lines 5 Install the pitman arm to the steering gear output splined shaft A timing mark is provided on the bottom of the pitman arm which is intended to line up with the steering gear timing marks on the gear case and output shaft When all three timing marks are aligned the pitman arm and gear are in the straight ahead position 6 With the pitman arm in place tighten the retaining fastener to the following torque level depending upon the manufacturer TRW 3 4 fastener 125 to 150 ft Ibs See Torque Specs on pages 6 amp 7 7 Connect the tie rod arm tapered ball joint ends to the mating end of the pitman arm and tighten the nut to 125 to 135 ft Ib Install cotter pin See Torque Specs on pages 6 amp 7 8 Bleed gear case per manufacturers recommen dations NOTE Refer to Steering Gear Manufacturer s service manual for other detailed information 9 Realign the vehicle per manufacturer s specifications or the wh
18. case is very heavy and a proper support device should be used dur ing removal A CAUTION Failure to properly support the steering gear could result in personal injury to hands or feet Removal 1 Apply the parking brake and block the drive wheels to prevent vehicle movement 2 Raise the front wheels off the ground and support vehicle with safety stands DO NOT support the vehicle with jacks or stands under the control arms A WARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury 3 Disconnect the tie rod assembly from the pitman arm at the tapered ball joint connection by removing the cotter pin and nut 4 Loosen and remove the 3 4 retainer fastener from the pitman arm The pitman arm can be lowered from the output shaft drive spline and removed NOTE Depending upon clearances it may be necessary to loosen and remove the steering gear case 7 8 attachment fasteners to allow the gear to be moved backward This will allow easier access to the pitman arm gear output shaft connection gt NEW AY Part Replacement continued 5 Disconnect all hydraulic lines and the steering input shaft to the gear
19. cessary Automatic Slack Adjusters and Brake System Automatic Slack Adjusters The suspension system is equipped with slack adjusters for steer axles For inspection and adjust ment procedures refer to the slack adjuster manufacturers technical service guidelines Brake System The suspension system comes equipped with Eaton 15 x 4or 16 1 2 x 5 S cam brake assemblies Fig 9 For service procedures refer to Eaton maintenance manual ZBRSM 0033 Figure 9 Brake System Pre Operational Inspection Continued ABS Sensor and Tone Ring Please refer to Coach Manufacturer s Manual for sensor type and proper maintenance guidelines Shock Absorbers Inspection Procedure Visually check for shock absorber oil leakage bent missing or broken components excessive corrosion or worn bushings If you find any of the above problems replace the shock Air Spring Air Spring Inspection Procedures 1 Secure the vehicle by setting the parking brake and blocking the drive wheels 2 Remove any build up of foreign material present around the air spring piston The air spring should be checked externally for irregular wear over extension or cracking 3 Make sure contact does not exist between the air lines and the outside diameter of the air spring Re secure air lines to prevent contact as needed Check for leaks along the air line and fittings with soapy water solution If leaks are found replace air line and or fittin
20. d be a proper ride height 3 If ride height is off adjust height control valve by loosening the hose clamps Fig 14 on the universal connection fitting Push up to raise ride height and push down to lower ride height Retighten hose clamps after adjustment NOTE If proper ride height is not obtained or air springs do not inflate properly check air pressure and pressure protection valve check for proper pip ing and repeat above steps Then if not functioning properly contact the chassis manufacturer or Holland Neway Service Department NOTE The Type IR HCV can be installed with the control arm in either left hand or right hand position Refer to Form 94100535 or contact Holland Neway Service Dept for information 12 IFS Series Suspension Figure 14 Type IR Height Control Valve Adjustment k lt Hose Clamps Universal Connection Valve Adjustment i gt NEWAY Lubrication Table 4 Lubrication Specification and Intervals Component On Ends of Tie Rods Relay Rod Drag Link Which ever comes first 50 000 miles 80 000 kilometers or once a year Brake S Cam Tube and Automatic Slack Which ever comes first Brakes relined 50 000 miles Service Interval Change Interval Lubricant Specification N A Multi Purpose Chassis Grease NLGI Grade 1 or 2 Lithium Base Multi Purpose Chassis Grease Adjuster 80 000 kilometers or once a NLGI Grade 1 or 2 Lithium Base Year Wheel E
21. e Align or adjust as required Power steering pump fluid level low Add fluid tighten connections and correct and possible leak in system as needed Power steering pump pressure and Conduct pump flow and relief pressure tests flow below specification and adjust repair or replace as needed Air in power steering system Add fluid tighten connections amp bleed system Contaminated or incorrect fluid Replace with correctly specified fluid Obstruction within steering gear or lines Inspect remove obstruction s and repair or replace as required Excessive internal steering gear leakage Inspect repair or replace as required Vehicle overloaded or unevenly loaded Check wheel loads and correct as needed Improper mismatched tires and wheels Install correct tire and wheel combination Incorrect toe in setting Adjust toe in to specified setting Vehicle wanders side lo Tires have incorrect pressure Put specified air pressure in tires side oose steering I heel has Loose steering gear mounting Check mounting and secure as needed visioni n m Tie rod end connection loose or ball stud worn Inspect ball stud connections and wear oscillations when hitting Loose wheel nuts Check and tighten to specification large bumps Ball joints binding or worn Inspect ball joints for wear or contamination and replace as required Steering column linkage worn Check for wear and repair or replace as needed Wheel bearings out
22. eel alignment section of this manual page 18 IFS Series Suspension 25 Troubleshooting Suspension System SIUE Fosses TREMEBES Put specified air pressure in tires Tires wear out quickly or have balance or replace tires uneven tire tread wear Adjust toe in to specified setting NOTE Wear pattern will indicate Adjust ride height to specified setting possible cause s Consult with Align rear axle to specified thrust angle tire manufacturer for guidance Adjust tie rod lengths as required Improper mismatched tires and wheels Install correct tire and wheel combination Improper oversized tires Install correct tire and wheel combination Tires not uniform Install correct tire and wheel combination vU Tires have incorrect pressure Put specified air pressure in tires Vehicle is difficult to steer Incorrect steering arm geometry Adjust tie rod lengths as required Steering arms binding Check steering arm bearings and lubricate as needed Ball joints binding Inspect ball joints for wear and replace as required Tie rod ends binding Inspect tie rod ends for wear and lubricate as needed steering column linkage binding Align or adjust as required oteering miter box binding Check steering miter box and repair or replace as required oteering gear valve binding Inspect repair or replace as required steering damper binding or malfunction Check and replace as needed steering wheel to column interferenc
23. els to prevent vehicle movement 2 Raise the front wheels off the ground and support with safety stands DO NOT support the vehicle with jacks or stands under the control arms AA WARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury 3 Remove the front tires Disconnect the Height Control Valve HCV linkage from the lower connection bracket Fig 11 page 10 4 Remove bolts that secure the air spring piston to the knuckle post mounting plate IFS Series Suspension 23 Part Replacement continued 5 Use a portable crane or jack and support the steering knuckle post assembly at its lowest position prior to disconnecting it from the con trol arm or removing the control arm with the steering knuckle attached The knuckle post assembly is heavy and unbalanced and must be properly supported A CAUTION Failure to properly support the knuckle post assembly could result in personal injury to hands or feet 6 Remove knuckle bolt cotter pins Loosen the knuckle bolt nuts and remove 7 Pull the knuckle post bolt assemblies from the upper and lower control arm connections and completely remove it 8 Swin
24. en replaced they must be replaced with fasteners of the same grade size and form as the original in order to prevent failure Bolt Grade Markings iF 2 SF Grade 8 Lock Nut Grade Markings Lock Nut Lock Nut Grade Grade B Grade C 33 Identification 6 Dots iD NEwAY IFS Series Suspension 29 Parts List Sway Bar Kit Item Part No Description Qty 90045372 Item Numbers 2 10 are available in Kit Number 90546699 NOTE Swaybar shown is NOT available with the following IFS Model Number configurations 790547128 2790547129 790547183 amp 790547185 CO 00 Ni Od O1 amp Go POT I FS 00 0o BB PO POT e IMPORTANT Most of the fasteners used in this suspension are graded fasteners These fasteners have the strength and hardness properties required for their particular function When replaced they must be replaced with fasteners of the same grade size and form as the original in order to prevent failure 30 IFS Series Suspension gt AE WAY Parts List Knuckle Post Assembly EN 1 4 3 L lt d j TA O NOD NOTE Quantities shown are for 1 one Knuckle Post Assy There are 2 two Assy s per suspension Item Part No Description Qty Item Part No Description Qty 1 see OEM Knuckle Post Assembly RH 13 see OEM 9 64 Cotter Pin 1 14 1 2 15 1 16 1 3 SeeOEM O Ring 17 4 18 5 18 6 18 7 19 1 8 20 1 9 21 1 10 22 1 11 23 1 12 24 1 Shim size a
25. es when performing the procedures covered in this manual Throughout this manual you will notice the terms NOTE IMPORTANT CAUTION and WARNING followed by important product informa tion So that you may better understand the manual those terms are as follows NOTE Includes additional information to enable accurate and easy performance of procedures 2 IFS Series Suspension Checking and Adjusting 15 Wheel Bearings 15 Maximum Turn Angle 16 Inspection Before Alignment 17 Front Wheel Alignment 18 Caster Angle Adjustment 18 Camber Angle Adjustment 19 Adjusting Toe In 19 Part Replacement 20 Parts Repalr 20 Parts Cleaning 20 Upper and Lower Control Arm 20 21 shock Absorber Replacement 22 Air Spring Replacement 23 Knuckle Post Connection 23 24 Steering Gear Replacement 25 Troubleshooting 26 27 Parts List Information 20 31 IMPORTANT Includes additional information that if not followed could lead to hindered product performance and or product failure CAUTION Used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in p
26. g the knuckle post outward or swing the control arms upper or lower aside until full access is available to the upper and lower bear ings NOTE Care should be taken to insure the roller bearing elements do not fall out by slowly moving the knuckle post or control arms aside 9 Remove the roller bearing elements and the O rings from both sides of the knuckle post opening Fig 30 Figure 30 Knuckle Post Connection Replacement eU A Cylind er EN Au oon mes De E 2 d Bolt Sleeve E y TS A Ec at x i Uer A Pn Bearin Soc Gy EM Outer ss Xo UN Bearing pore wm y i 3 Race E A 1 i 10 If the outer bearing race needs to be removed a long flat nosed punch will be required to gently tap out the outer race from the back side of the race NOTE The area will likely be filled with grease and the grease will need to be removed to allow a clear view of the inside inner edge of the bear ing cups 11 Remove the cylindrical bolt sleeve Installation 1 Place the cylindrical bolt sleeve s in the knuckle post opening 2 If removed install new outer bearing races into the knuckle post opening s by gently tapping in the race with a block of wood placed between the race and the hammer Fig 30 NOTE It is very important to completely seat the bearing race in the knuckle post receptacle A 0 002 feeler gage should not fit between the backside of the race and the mating shoulder in t
27. gs 4 Make sure the air spring while energized with air has a minimum of 1 inch clearance around its circumference Fig 10 5 Refer to Air Spring Manufacturers Preventative Maintenance Checklist for additional formation Figure 10 Air Spring Check 1 Min Clearance Required Around Air Spring 10 IFS Series Suspension Height Control Valve Inspection Procedures 1 Check the height control valve and linkage assembly for damaged parts and replace them Fig 11 2 Measure the ride height of the suspension Fig 12 Measure the distance from the bottom of the chassis frame rail to the center of the wheel An alternate measurement may be taken between the center of the shock mounts See Chassis builder manufacturer for correct ride height The vehicle can be empty or loaded while taking these measurements NOTE An alternate way to measure ride height is to measure from centerline of spindle to ground A dim and from frame rail to ground B dim Then subtract A from B to establish ride height measurement Fig 12 Figure 11 Height Control Valve Linkage Assy Type IR HCV Shown lt Control Arm Height Control Valve Linkage IR shown Assembly Lower Linkage Brackets connection could vary per vehicle Figure 12 Ride Height Measurement Ground Line Bottom of Bottom of x Chassis Chassis I Frame Frame P WA ae Height x A Adjust
28. h Builder must be referred to for the straps etc to Control Arms upper or lower Sway recommended towing methods Bar Brake Components Tie Rods or Knuckle Post Assemblies Fig 4 NOTE Before towing vehicle check with local authorities Department Of Transportation for A WARNING permissible towing methods Some States DO NOT Attaching towing equipment to improper permit towing vehicles by chains or towing straps locations and failure to utilize OEM Coach Builder recommended towing methods could result in one or more of the following e Damage to the suspension and or vehicle Loss of vehicle control e Possible disconnect from the vehicle Figure 4 Improper Tow Equipment Attachment Locations DO NOT attach towing equipment to any of the identified components Brake Chamber amp Components Knuckle Post my Lom 3 P Tie Rod Lower Control Arms iD wewvAv IFS Series Suspension 5 Introduction Continued Torque Specifications Figure 4 IFS Pre Operational Torque Checklist IMPORTANT Most of the fasteners used in this suspen sion are graded fasteners These fasteners have the strength and hardness properties required for their particular function When replaced they must be replaced with fasteners of the same grade size and form as the original in order to prevent failure Table 2 Torque Chart Fastener Size Fastener Torque Specification Item Application Bolt Dia x
29. he knuckle post IMPORTANT Care should be taken to insure the bearing race surface is not damaged 3 Prepack the roller bearing elements with grease and apply grease to the outer bearing races and machined faces of the control arms 4 Place the roller bearing elements and O ring in each side Typically the grease will hold the roller elements in place until the control arms are moved into place 5 Swing the knuckle post or control arm ends into alignment with the bore of the tapered roller elements NOTE Care should be taken to insure the O ring does not get pinched between the knuckle post control arm and roller element bore O Ring 6 Insert the knuckle post bolt assembly through the c connection e 7 Install nut and torque to 630 770 ft Ibs Install AD cotter pin See Torgue Specs on pages 6 amp 7 GE L 7 t c 8 Re lubricate connection per lubrication instruc Cylinder Outer gs u tlons on page 15 earing I O Ring ien Sleeve Rare 9 Replace bolts that secure the air spring piston to the knuckle post mounting plate 24 IFS Series Suspension CD AE vv lv steering Gear Replacement Procedure NOTE Not all IFS units are fitted with a steering gear supplied by Holland Neway The approximate weight of each gear with fluid is between 80 and 100 Ibs and may require some external means to support it during removal See chassis manufacturer for detailed steering gear information IMPORTANT Steering gear
30. in should be measured and adjusted Toe in usually has the largest effect on tire wear See Maintenance Schedule Chart on page 3 NOTE Maximum wheel turn angle should also be checked and adjusted refer to page 16 NOTE Adjusting the length of the drag link or tie rods to center the steering wheel could cause the steering gear to become off center IFS Series Suspension 17 Checking and Adjusting continued Caster Angle Adjustment AWARNING Adjusting the ride height or altering com ponents to adjust the suspension caster is strictly prohibited Alteration of components could result in loss of vehicle control NOTE Caster is preset at the factory and should not need to be adjusted If adjusting is needed the camber adjuster shims can be used for caster adjustment By offsetting the number of shims on the front lower control arm connection to the number of shims on the rear lower control arm connection Fig 22 amp 24 a change in caster will occur Figure 22 Caster Angle Adjustment Rear Lower Arm Connection Front Lower Arm Connection 18 IFS Series Suspension Table 5 Nominal Caster Values Suspension Parts List No Degrees 90546687 3 0 1 90547128 4 5 x 1 90547129 4 5 x 1 90547183 4 5 x 1 90547185 4 5 x 1 Caster is pre set at the factory NOTE The knuckle post casting has a large embossed number near the king pin hole This number designates the pre set caster angle
31. ing Bolts 8 total Tie Rod Ends A WARNING DO NOT use wrenches or other similar objects to apply leverage when inspecting tie rod sockets This could cause incorrect results and damage components leading to loss of steering control Inspection Procedure 1 Secure the vehicle by setting the parking brake and blocking the drive wheels 2 Turn the engine on and rock the steering wheel lightly Observe any looseness in the mating tapers or movement of the stud nuts at both ends of the tie rod Fig 8 If looseness is found go to step 3 otherwise move forward to step 4 IFS Series Suspension Pre Operational Inspection continued 3 With the engine off remove the tie rod end ball stud from the taper mount and visually inspect both If either of the mating tapers show distortion or wear then both components must be replaced See Torque Specs on pages 6 amp 7 4 With the engine off and the wheels straight ahead grasp the tie rod near its end Fig 8 and try to move the socket in all directions Be sure to only apply hand pressure to the tie rod 5 The side to side movement Arrows A amp B Fig 8 of the socket must be measured with a scale If it moves more than 1 8 inch 3mm then replace the tie rod end immediately If there is detectable movement but it is less than 1 8 inch 3mm then the tie rod end should be replaced before it gets worse 6 Check dust boot for damage and replace if ne
32. ing Suspension Ride Height NOTE Before performing any adjustment or main tenance identify the style of the height control valve The IFS suspension can be equipped with either a Holland Neway Type CR Controlled Response or a Type IR Immediate Response height control valve Follow the proper adjustment procedures for your height control valve The height control valve and linkage should be checked frequently for proper clearance operation and adjustment NOTE Improperly adjusted ride height will result in incorrect alignment measurements and may result in poor ride quality and abnormal tire wear Check ride height prior to front suspension alignment The front suspension ride height is the distance between the bottom of the chassis frame rail to the center of the wheel spindle Fig 12 Properly adjusted ride height results in correct suspension travel and alignment DO NOT adjust the ride height to adjust chassis rake angle Adjustment Procedure Type CR Valve Park the vehicle on a level surface and secure the vehicle by setting the parking brake and blocking the drive wheels gt NEW AY Pre Operation Inspection continued 2 Pressurize the air system with a constant supply of air in excess of 105 P S I G All air springs should inflate and be set to the chassis manufac turers ride height 3 Make sure the rear suspension is adjusted to the correct ride height per the vehicle manufacturers specifications
33. l arm bushings and damaged suspension components need to be replaced 4 Inspect for wear and replace and tighten all loose ball joint and tie rod end tapered connections tie rod end jam nuts steering arm mounts and chassis steering system components 5 Check the wheel bearings and adjust as needed 6 Inspect all shock absorbers for possible wear and damage gt NEW AY Front Wheel Alignment AWARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury NOTE Refer to OEM Chassis Manufacturer for proper alignment procedures Follow the manufacturer s procedures to prepare the vehicle for front and rear wheel alignment measurements IMPORTANT Holland Neway recommends that professional alignment equipment be used to measure the wheel alignment characteristics caster camber and toe in The equipment must also be properly calibrated Only qualified personnel should conduct the wheel alignment measurements IMPORTANT Toe in of the front wheels should be checked every 24 000 miles or 2 years If the vehicle does not steer correctly or the front tires develop an abnormal tire wear pattern the caster camber and toe
34. lubricate as needed Inspect for defects and replace as required Adjust slack adjuster as required Replace with same size brake air chambers and length slack adjusters Check side to side air pressure and correct as needed Check side to side stroke and adjust as required Check and adjust as required Check fittings with soapy water solution and remove obstruction Check chamber for air leak and damaged diaphragm Replace shock absorbers as needed Check and tighten as required Check and replace as needed Inspect and replace as required Check height control valve and replace as required 27 Parts List Sub Frame Assembly VEHICLE FRONT 28 IFS Series Suspension iD ewAY Parts List Sub Frame Assembly Item Part No Description Qty Item Part No Description Qty 1 4 24 3 2 1 25 3 3 1 26 4 4 1 27 5 5 2 28 2 6 1 29 2 7 8 30 1 8 8 31 2 9 4 32 1 10 8 33 2 11 4 34 2 12 8 35 1 13 16 36 2 14 8 37 HCV Linkage Assy not shown 2 15 4 38 2 16 8 39 4 17 2 40 2 18 4 41 4 19 4 42 4 20 4 43 4 21 4 44 4 22 4 45 2 23 3 46 3 4 10 x 4 5 GR5 Bolt 1 23A 1 47 32 NOTE Part numbers for major suspension com ponents will vary by suspension model part number Contact the vehicle OEM for proper component part number IMPORTANT Most of the fasteners used in this suspension are graded fasteners These fasteners have the strength and hardness properties required for their particular function Wh
35. nd 1000 miles 1600 kilometers Which ever comes first Seals Gear Oil Check fluid level replaced brakes relined 100 000 miles 160 000 km or once a year SAE 80W 90 or equivalent Moly disulfide type grease is not recommended since it may lower friction capabilities in the adjusting clutch parts of the automatic slack adjuster General Lubrication It s important to use proper lubrication practices to gain maximum service life for your Holland Neway Independent Front Suspension IMPORTANT DO NOT mix 2 lubricants of different grades DO NOT mix mineral and synthetic lubricants Parts may experience pre mature failure Different brands of the same grade may be mixed IMPORTANT Never mix oil bath and grease packed wheel ends Parts may experience pre mature failure Greasing Knuckle Post Assembly The knuckle post assembly Fig 15 is designed to be a factory installed assembly that is permanently greased for the life of the vehicle The joints are sealed by four 4 O rings on each knuckle post assembly designed to hold in grease under pressure while preventing outside contamination Although greased at the factory two 2 Zerk style grease fittings have been installed on each knuckle post assembly Fig 15 This allows re application of grease after maintenance or Figure 15 Knuckle Post Assembly Upper Grease Fittings replacing components Lower Grease Fitting gt AE Wf Recommended Procedure
36. nd quantity is determined during the manufacturing process T NEwAY IFS Series Suspension 31 Quality System Certified 1950 Industrial Blvd Muskegon MI 49443 Phone 888 396 6501 Holland USA Inc Facilities Denmark SC Dumas AR Holland MI Milpitas CA Ph 888 396 6501 Muskegon MI Warrenton MO Whitehouse Station NJ Wylie TX Fax 800 356 3929 GO THE DISTANCE HOLLAND USA INC www thehollandgroupinc com Copyright January 2002 The Holland Group Inc Holland International Inc Holland MI Phone 616 396 6501 Fax 616 396 1511 Holland Hitch of Canada Ltd Woodstock Ontario Canada Phone Fax 519 537 3494 800 565 7753 Phone Fax e Fax 800 356 3929 Holland Equipment Ltd Norwich Ontario e Canada 519 863 3414 519 863 2398 Holland Hitch Western Ltd Surrey British Columbia Canada Phone 604 574 7491 Fax 604 574 0244 XL AK397 01 Print Qty 4M
37. of adjustment Check wheel bearing end play and adjust as required oteering gear adjustment Check and adjust to specification oteering column mis aligned Realign steering column as required oteering arm mounts loose Check and tighten to specification 26 IFS Series Suspension iD ewAY SYMPTOMS Vehicle pulls to one side without the brakes applied Vehicle pulls to one side with the brakes applied Vehicle rolls side to side excessively gt NEW AY Troubleshooting Suspension System continued POSSIBLE CAUSES Improper mismatched tires and wheels Tires have incorrect pressure Vehicle unevenly loaded Improper brake adjustment Incorrect rear axle alignment Unequal ride height side to side Wheel bearings out of adjustment Loose steering gear mounting Tie rod end connection loose or ball stud worn Bent spindle or steering arm Frame or underbody out of alignment Incorrect toe in setting Mis aligned belts in radial tires steering gear valve binding Steering gear not centered Excessive internal steering gear leakage Incorrect caster and or caster setting Grease oil or dirt on brake linings Brake linings are glazed Brake linings are not a balanced set different friction codes or lining brand Loose or broken brake linings Brake drum out of round Defective brake drum Brake air chamber clevis pin or camshaft binding Defective slack adjuster Uneven brake adjustment
38. rect wheel turn angle is achieved and the bolt head contacts the steering arm 5 Tighten the jam nut to 90 110 ft Ibs See Torque Specs on pages 6 amp 7 NOTE Refer to OEM Chassis Manufacturer for proper alignment procedures gt NEW AY Checking and Adjusting Continued IMPORTANT After readjustment of the steering stop s make sure the steering poppets are reset properly and the front tires DO NOT contact the frame suspension or body A 1 2 minimum clearance between the air spring and brake dust cover is required Failure to maintain 1 2 clearance may result in air spring and or tire damage 6 Repeat Adjustment Steps 1 thru 5 for turning the opposite direction Inspection Before Alignment Before conducting front wheel alignment measurements check the following requirements Wheels and Tires 1 Inflate the front tires to the appropriate pressure based on the wheel loading The front tires need to be the same size and type 3 Make sure the wheel nuts are tightened to the specified torque of 450 500 ft Ibs See Torque Specs on pages 6 amp 7 NOTE Refer to OEM Chassis Manufacturer for proper alignment procedures 4 Check if the wheels are balanced Use standard procedures Front Suspension 1 Torque all fasteners to the right specifications 2 Check the suspension ride height and adjust as needed to the specified height 3 All worn ball joints tie rod ends steering arm bearings contro
39. removing or replacing Fig 27 5 Bushing hole of the control arms should be free of any burrs before replacing new bushings 6 Using the same hydraulic press from step 3 push new bushing back into the control arm housing while supporting it securely 7 Place the control arm in its mount location and install the control arm mount bolts into sub frame snug tight 8 Reconnect lower control arm to the knuckle post assembly 9 The control arm should be supported in such a way such that it is at ride height then torque the bolts to the recommended torque specs See Torque Specs on pages 6 amp 7 NOTE Improperly adjusted ride height will result in incorrect alignment measurements and may result in abnormal tire wear Check ride height prior to front suspension alignment see pages 10 12 Wheel Bearing Oil Seal and Hub Cap Replacement See Coach Manufacturer s Service Manual for replacement guidelines 22 IFS Series Suspension Shock Absorber Replacement AA WARNING Shock absorber is gas pressurized DO NOT puncture of expose to excessive heat serious personal injury can result Preparation 1 Apply the parking brake and block the drive wheels to prevent vehicle movement Removal 1 Remove the 3 4 10 lower shock absorber mounting bolt from the Knuckle Post Shock Bracket Fig 28 Figure 28 Shock Absorher Shock Absorber Mounting Bolts 2 Remove the 3 4 10 upper shock absorber moun
40. roperty damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury gt NEWAY Introduction Table 1 Maintenance Schedule General Maintenance Service to be performed Mileage in the Thousands X 1 000 12 24 se 4e eo 72 e o cO Control Arm Bushings Gneck tor propertorqueonbots L X X X x Upper and Control Lower Arms Inspect for contact between Control Arm and Mount Brkts X e Tie Rod Ends Inspect ball socket end play X Check for looseness of taper connection X Check that cotter pin is installed X Brake System Inspect slack adjuster for correct stroke x retrain were Ex LL L Air Springs Inspect for proper clearance 1 minimum all around X f Check upper mount nut and lower mount bolt torque x Inspect for signs of chafing or wear X Check for air line fitting torque x Inspect for air leaks using soapy water solution EXEC OD kT Height Control Valve Linkage eee x Shock Absorbers Check stud mount and lock nut torque Inspect shocks for signs of fluid leak broken eye PUPPI X ends loose fasteners or worn bushings oteering Arms Check for proper torque on nuts re ve lpg XIX xe ee Wheels Check bearing end play LOT ey gt Check for proper torque on wheel nuts X Fron
41. s between 001 005 inch secure with new cotter pin Replace hub cap refer to Table 3 on page 7 for proper torque specifica tions 15 Fill the hub cavity with the prescribed amount and type of lubricant See Table 4 on page 13 for lubricant specifications 16 Install drain plug 17 Repeat for other wheel IFS Series Suspension 15 Checking and Adjusting continued Maximum Turn Angle Adjustment IMPORTANT DO NOT adjust angle more than 50 An over adjustment of the turn angle can cause damage to system components 1 Check the turn angle if the front tires rub against the frame suspension body or if the steering gear has been serviced Use an alignment machine to check the angle NOTE Follow the alignment machine manu facturers alignment procedure 2 The maximum turn angle is controlled by the steering stop bolt located on the spindle assem bly Fig 21 If the stop bolt is bent broken or missing replace the stop bolt s or jam nut s and follow the procedure below for adjustment Inspect other suspension components for damage 3 While adjusting the steering stop s the steering gear poppet valves may also need readjustment Refer to Steering Gear Manufacturers Service Manual for readjusting the poppets IMPORTANT In power steering systems hydraulic pressure should relieve or drop off when the turned wheels approach the steering stops in either direction The front suspension components ma
42. s use safety stands Never work under a vehicle supported by a jack s only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury Inspection Procedures 1 Secure the vehicle by setting the parking brake and blocking the drive wheels 2 Jack the vehicle up to raise the front wheels off from the ground Support the vehicle with safety stands pU S Remove the tires Look for bushing bulge between the upper and lower control arms and the sub frame mounting brackets Look for small rubber particles near the sub frame mounting brackets Fig 6 amp 7 If either condition is found replace bushings 6 Look for loose mounting bolts 8 places in the upper and lower control arms Fig 6 amp 7 Make sure that the mounting bolts are tight A loose joint will result in wear between the bushing inner sleeve and the subframe mounting brackets See Torque Specs on pages 6 amp 7 NOTE It is recommended that if one bushing is found to be worn all control arm bushings must be replaced See page 20 for bushing replacement Figure 6 Upper Control Arm to Sub Frame Connection p i a f fa i 4 F a Figure 7 Lower Control Arm to Sub Frame Connection Lower Control Arm Mount
43. shers from the upper air spring mounting studs 3 Remove bolts that secure the air spring piston to the knuckle post mounting plate Fig 29 4 Remove the air spring Figure 29 Air Spring Replacement Upper Air Spring Mounting Studs Air Spring Piston Knuckle Post Mounting Plate Part Replacement continuea Installation 1 Mount the air spring to the knuckle post mount ing plate Torque the bolts to 30 40 ft Ibs See Torque Specs on pages 6 amp 7 2 Assemble the nuts and washers that connect the air spring to the upper air spring mount on the subframe Torque the nuts to 30 40 ft Ibs See Torque Specs on pages 6 amp 7 3 Install connection fitting into the air spring Use Permatex or equivalent thread sealant Connect air line to the air spring 5 Lower vehicle frame and inflate the air springs Use water liquid soap spray to check air fittings for leaks Knuckle Post Connection Replacement IMPORTANT The Holland Neway IFS utilizes precision roller bearings at each upper and lower knuckle post connection This connection is very robust and tightly toleranced for ease of assembly and repair Care should be taken to insure the machined surfaces of the control arms and bearing races are protected from damage If a bearing element needs replacement it is strongly suggested the outer bearing race be replaced at the same time Removal 1 Apply the parking brake and block the drive whe
44. side to side Different brake air chamber size or Slack adjuster length side to side Air pressure uneven side to side Unequal brake air chamber stroke side to side Rear axle brakes mis adjusted Air leak or obstruction in air brake lines Brake air chamber air leak or diaphragm damaged Front and or rear shock absorbers worn shock mounting loose shock eye bushings worn Control arm pivot bushings worn Internal leak in height control valve IFS Series Suspension REMEDIES Install correct tire and wheel combination Put specified air pressure in tires Check wheel loads and correct as needed Inspect adjust and correct as required Align rear axle to specified thrust angle Check ride height and adjust to specified setting Check wheel bearing end play and adjust as required Check mounting and secure as needed Inspect ball stud connections and wear Inspect and replace as required Inspect and correct as required Adjust toe in to specified setting Check and replace as needed Inspect repair or replace as required Inspect and adjust as required Inspect repair or replace as required Install and or adjust eccentric adapters in upper control arm Replace brake linings as required Deglaze brake linings or replace as required Replace brake linings as required Replace brake linings as required Re machine brake drum as required Inspect for defects and replace as required Check and
45. t bolt Fig 28 Installation Install the shock absorber into the upper mount ing bracket and secure with mounting bolt 2 Place the shock absorber into lower mounting bracket and secure with mounting bolt 3 Torque bolts to recommended specifications See Torque Specs on pages 6 amp 7 i gt NEWUAY Air Spring Replacement IMPORTANT When replacing the air spring make sure you use the correct replacement Using an air spring that is not recommended by Holland Neway may be detrimental to vehicle ride and handling Preparation 1 Apply the parking brake and block the drive wheels to prevent vehicle movement 2 Raisethe vehicle until the front wheels are off the ground Then support the vehicle with safety stands DO NOT place jacks or safety stands under the lower control arms to support the vehicle A WARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury 3 Remove the front tires Disconnect the Height Control Valve HCV linkage from the lower connection bracket Fig 11 page 10 Removal 1 Remove air line at the air spring then remove the connection fitting 2 Remove all nuts and wa
46. t Alignment Inspect toe in X x X X Air Fittings and Air Lines Inspect for air leaks using soapy water solutions X XL T Inspect airlines for signs of chafing cracking or wear X xf xf xi xf xix X 1 Wheel nuts must be re tightened to proper torque specifications as per the vehicle or chassis manufacturer s Owner Guide 2 Continue to perform specified maintenance every 12 000 miles 3 Toe in should be inspected after vehicle completion by final stage manufacturer iD NEwAY IFS Series Suspension 3 Introduction continued serial Number Tag Location The IFS Series Suspension Serial Tag is attached to the forward front subframe bulkhead Fig 1 Stamped on this tag are the suspension model and serial number and parts list number Fig 2 The serial number is used by Holland Neway for control purposes and should be referred to when servicing the suspension NOTE This manual applies to the suspension series shown on front cover However we urge you to reference your specific parts lists number write that information below and use it when obtaining information or replacement parts Holland Neway reserves the right to modify or change the suspension described in this manual its specifications and its repair and maintenance procedures at any time with out notice or incurring any obligation MODEL NUMBER SERIAL NUMBER PARTS LISTS NUMBER IN SERVICE DATE Figure 1 Serial Number Tag Location Serial Num
47. y be damaged if the pressure does not relieve AWARNING Always use safety stands Never work under a vehicle supported by a jack only Jacks can slip or fall over and cause serious personal injury DO NOT place jacks or safety stands under the lower control arms to support the vehicle Lower control arms are not stationary components and could move allowing the vehicle to drop causing serious personal injury 16 IFS Series Suspension Figure 21 Steering Arm Stop Bolt i dilema M Steering Arm Stop Bolt IMPORTANT Unequal toe in side to side or an off center steering gear can result in unequal turn angles and steering pull while steering straight ahead The drag link length may be adjusted to attain steering gear on center condition while maintaining equal toe in side to side Failure to obtain equal toe in or on center steering gear may result in premature tire wear IMPORTANT DO NOT adjust the length of the drag link or tie rods to center the steering wheel This can cause the steering gear to become off center and result in premature tire wear Adjustment 1 Turn the steering wheel until the steering arm contacts the stop bolt or stops turning Fig 21 Measure the turn angle of the wheel on the same side as the turn 1 e inside wheel 2 Ifthe wheel turn angle differs from the chassis manufacturer guidelines adjust as follows Loosen the stop bolt jam nut 4 Rotate the stop bolt until the cor
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