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1. Monroe 65427 Gabriel 85903 Monroe 66886 Gabriel 85014 Monroe 65110 Gabriel 85005 Air Springs Goodyear Air Spring Conti Air Spring Conti 9 10 19 5 A801 Firestone W01 358 9580 M Firestone n a i 000003 C0060 Goodyear 1R12 467 S20127 M 1000001 C0079 Goodyear 1R12 494 pent 9 10 17 5 A 802 c0096 Goodyear 1R12 256 1R12 580 ma Conti 11 10 5A 16 P523 1R14 151 C0073 Goodyear 2B12 440 Wk FD 331 26 480 lEirestone W01 358 7550 Conti FD 200 25 429 C0080 Goodyear 2B9 251 Firestone W01 358 6948 1003586948C Conti FD 530 35 545 S 2734 Replaces 7136 S 1080 poe FD 530 30 449 1003586801 C C0083 Goodyear 2B14 365 Firestone W01 358 6801 cor 64 Goodyear 2B14 366 Giving the World a Better Ride pw eraser October 10 20072. CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Suspension to Axle 3 Pass Weld Sequence UnderMount or TopMount FIGURE 1 Axle Weld Pass sequence Axle Welding Procedure A0001 2 1 2 Weld Seat For 10 000 to 30 000 Axle Capacities Root Pass After Root Weld Hit Tabs Down rd A 38x 50 NO WELD 1 8 From Ends On 3rd Passes US A J Pub P1203 01 Rev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Axle Welding Procedure A0003 1 3 8 Weld For 6000 to 10 000 Axle Capacities Root Pass After Root Weld H Tabs Cowr Boe teat tet tate te te 2nd Pass October 10 2007 Giving the World a Better Ride Pub P1209 09 Fev CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Recommended Frame Welding Sample Drawing Call Cush For Your Application Sheet 3 C Giving the World a Better Ride pu p227 fev o CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Aftermarket Parts gt ross Reference Guide P1203 1 Appendix B Updated 3 2 200 Alt Alt Cross Reference Fl yeree Vendor 1 Vendor 2 Hendrickson Ridewell Corp Vendor Shock Absorbers Monroe STD 65416 Monroe HD 70720 Gabriel 85000 B 23566 STD A 20002 1270563B000 STD Monroe HD OE11494 Monroe HD 65493 B 24023 HD B 24125 65493 70720 ExtServ 1270563B003 HD Monroe 65421 Gabriel 85030 Monroe Gabriel 85064 B 23649 STD
3. alignment on street side for Spring Suspensions The T Align was designed to give our customers that use a leaf spring suspension axle adjustability at the frame hanger rather than having to loosen u bolts and adjust at the axle seat The T Align is a positive adjustment that works with springs to eliminate springs affecting the alignment process Overview The T Align pivot joint features a yoke assembly that covers the alignment slot After alignment clamp the joint per Cush torque specifications No weld is required to secure the slip joint after proper tightening e Remove load from trailer empty Jack the trailer up on a level surface and place appropriate jack stands of sufficient strength capacity to support the load under the axle near the spring seat areas e Tighten all fasteners on the R H Curb Side of trailer suspension e Check that the keeper bolts are not clamping the sides of the springs causing them to be locked by the rear hangers or equalizer e With ratchet turn the alignment bolt on the yoke assembly L H ROAD SIDE so that the pivot bolt is at the CENTER OF THE SLOT on the front hanger amp equalizer DO NOT USE AN IMPACT GUN Fig 1 e Hand tighten snug the pivot nuts of the T Align to be tight enough to hold the joint together but loose enough to permit forward movement of the alignment yoke able to loosen by hand e Block the top side of each equalizer between the frame with 2 blocks 3
4. 1 2 welds to prevent tampering amp for off road applications e f realigning loosen the rack lock bolts to allow eccentric cam movement e The eccentric cam gear should always have the 2 square hole to the top e Set the alignment gear indicator tab at 6 o clock the neutral position Snug the rack lock bolts and pivot bolts of the Trac Align to be tight enough to hold the joint together but loose enough to permit use of the eccentric cam adjustment Be sure that the eccentric cam plate is clamped down flush against the hanger side and is not riding up the grounding nuts bars e For adjustment use a breaker bar in the 2 square hole or use a box wrench on the lower eccentric cam gear nut e The Trac Align gives you 3 8 pivot movement fore and aft per hanger side see Figure 1 Figure 1 e To align the axle rotate the alignment gear of one side of the suspension to get the axle aligned If needed go to the other side of the suspension and rotate the alignment gear in the opposite direction to fully align the axle TRACK ALIGN Pivot amp AudiTorx AS Fig ure 2 WARNING After alignment clamp the pivot bolt per Cush torque specifications Torque the 1 2 rack lock bolts to 25 ft los loosen the rack lock bolts to realign pivot October 10 2007 USH Giving the World a Better Ride Pub P1209 09 Fev 6 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Alignment Style 4 T Align 3 8
5. 1 8 tall per side to keep level Fig 2 e Measure from the trailer s kingpin to determine the alignment required on the front axle L H ROAD SIDE to within 1 16 e After achieving proper alignment of the forward axle torque pivot fasteners per Cush installation drawing e Align additional rearward axles to within 1 16 tolerance of the forward axle per the T Align method FORWARD A ALIGNMENT ON gt H lt f 1 Giving the World a Better Ride pw eras aov 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Shock Absorber The shock absorber is used to dampen the bouncing of an air spring suspension Without shocks in place damage can occur to the suspension or trailer Shocks are a replaceable item of an air Suspension and when maintained can extend the life of your air Suspension and trailer Some things can indicate it is time to replace shocks Uneven tire wear poor ride characteristics broken or torn air springs Inspection o Broken upper or lower shock eye mounting at the welds Worn out upper or lower shock eye bushings Broken dust tube cover Bent or dented lower shock body tube Bent shock rod Shock leaking streams of oil O O00 0 0 To replace a shock absorber e Contact your trailer manufacture or Cush Corp for replacement parts or cross reference e Remove the shock end mounting hardware e Check the mounting surface for wear problems e Insert the new shock absorber an
6. hangers e Lower the axle beam assembly check for any damaged beam wear e Check that the wear washers are in usable condition e Check that the bushing inserts are in usable condition e Mark the hanger position on the frame side for reference e Cut away the frame hanger and clean up the frame with grinder do not gouge frame e Put new hanger component on beam bushing and reassemble the pivot connection use new pivot bolts amp nuts e Move the alignment gears to the nominal notch position and snug up hanger bolt e Raise the axle beam hanger assembly to the frame and clamp hanger to frame squarely e Weld hanger to frame per Cush Corp installation drawing e Reassemble any other parts that were disassembled to lower axle beam assembly e Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment e Torque all the fasteners to specification Warranty Labor Allowance__ 4 0 hours each or 6 0 hours axle See the troubleshooting guide for more information on frame hanger issues AUS Giving the World a Better Ride Pub P1203 0 Fev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Suspension Frame Hanger Bolt on type To replace a bolted frame hanger e Contact your trailer manufacturer or Cush Corp for replacement parts On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all
7. nuts e Reassemble any other parts that were disassembled to lower axle beam assembly e Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment e Torque all the fasteners to specification Warranty Labor Allowance 2 0 hours axle See the troubleshooting guide for more information on wear washer issues Cush Corp Suspension Fabricated Components Some issues are discussed here but if other deficiencies occur contact your trailer manufacturer or Cush Corp for information Suspension Frame Hanger Welded type Cush manufactures various hangers for different applications because of this it would be best for you to contact Cush for an installation drawing per your application On these drawings we show recommended cross member and support locations Failure to have the proper support in place can cause a reoccurring failure mode If for some reason it is required to replace a frame hanger please follow the guidelines below as a minimum safety procedure when repairing these items To replace welded frame hanger e Contact your trailer manufacturer or Cush Corp for replacement parts e On level ground securely chock the tires and apply trailer parking brakes e Support the trailer in a safe manner at a working height prior to exhausting the air e Exhaust all air from the air suspension system e Disassemble the pivot connection and any other parts that interfere with lowering the axle beam assembly out of the suspension
8. or the edge of the wheel rim you will not need to remove this equipment Measuring from the trailer s kingpin determine the alignment of the forward axle After achieving proper alignment of the forward axle torque the Cush Pivot fasteners per Cush torque specifications on the Cush installation drawing Align to within 0 063 tolerance any additional axles to the forward axle per the Cush Align method Use a commercially available alignment gauge or trammel bar if available see Figure 2 ANGE 116 Figure 2 Std Warranty Labor Allowance __ 0 5 hours axle NOTE Failure to follow the procedure for your axle alignment application and or properly torque the pivot fasteners can result in a failed pivot connection and a loss of warranty coverage AUS Page 7 Giving the World a Better Ride Pub 1203 01 Aev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Alignment Style 1 Cush Align Original 1 alignment inner flanged collars 1 4 thk gears The Cush Align pivot joint features outside gear tooth washers that cover the alignment slot and mate with a grounded rack plate At the inside of the hanger collars guide the bushing and cover the alignment slot e lf realigning and the gear washer is welded to the side of the hanger grind the welds loose without gouging the side of the hanger Remove the gear washers and clean away weld material e Snug the bolts of the Cus
9. signs of wear or component interferences Check each of the following e Fasteners Not loose broken or missing e Pivot Bushing Not protruding off center torn or worn e Pivot Washer Not worn through or torn e Chain Restraint Not elongated or broke e Shock Absorber Not leaking or damaged e Air Spring Not leaking worn or damaged e Air Control Trailer maintains ride height no leaking or damaged valves fittings or piping e Frame Hanger Not worn cracked bent or damaged e Suspension Beam Not worn cracked bent or broken e Beam Axle Not cracked bent or broken e Tires No tire wear that might indicate an alignment problem e Axle Alignment No pivot gear movement or inappropriate wear axles tracking properly Giving the World a Better Ride puw praosos Ses 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL e Trailer Trailer not leaning trailer frame suspension attachment structurally sound no cracked or missing welds at suspension frame attachment 90 day Inspection and at every brake lining change Thoroughly check all items checked at the 30 day inspection Also check e All welded connections for signs of deterioration e All frame attachment joints and pivoting or clamping joints for problems Axle Alignment Inspection Check the Cush Align connection for change of position at 30 day 90 day and every brake lining change Re align if necess
10. the Cush units Torx E 20 as provided by Hendrickson Camcar Strong Tools amp Apex If a Torx E 20 socket is not available torque bolt nut per 7 8 Grade 8 spec 550 600ft lbs The AudiTorx Shear type bolt gives automatic torque clamping and consistent repeatability because the Shear type Torx E 20 drive head is designed with a cut groove to shear off at a pre determined torque level when applied with an air impact After shearing off the Torx drive head a 36mm hex head is left for later service with a socket or wrench CUSH ALIGN Pivot amp AudiTorx Pa TRACK ALIGN Pivot amp AudiTorx a sin Y Torque FI sheared wel off E 20 3 AudiTorx Installation amp Inspection Notes o Required Materials E 20 Torx socket 1 5 16 nut wrench Air Impact wrench capable of 600 ft lbs 813 N m Minimum alignment tools o Ifa Torx E 20 socket is not available torque bolt nut per 7 8 Grade 8 spec 550 600ft lbs o DONOT APPLY undercoating to the suspension hanger area until after axle alignment and pivot bolt torque has been applied o Cush does not recommend reuse of pivot fastener hardware once the pivot connection is disassembled use a new bolt and nut o Check for proper tire clearance with fastener hardware The AudiTorx bolt should be installed from the inboard side of the frame hanger to allow access with an air impact when tires are on if tire clearance is an issue with fastener hardware then the shear type b
11. the HCV handle horizontal arm thru the hole to the HCV and adjust the vertical linkage e Mount the vertical linkage bottom pin in place to the closest hole when using a fixed vertical link e Mount the vertical linkage bottom pin in place and adjust the link in the p grommet and clamp the grommet collar in place when set with the handle pinned to the HCV center position e Caution Remove HCV centering pin otherwise damage to HCV could occur Reference Warranty Labor Allowance__ 1 0 hours each Contact Original Manufacturer AU Giving the World a Better Ride Pub P1203 01 Fev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Barksdale Height Control Valve Installation Physical Description The Barksdale Height Control Valve HCV is a three mode valve used to control the height of a vehicle by directing air to the air spring suspension The main physical features of the valve are the following 2 delivery ports 1 Exhaust port 1 inlet supply port 1 Height Control Handle and 2 4 Mounting Studs All ports are 4 NPT the 2 delivery ports are clearly marked C1 and C2 on the back of the valve Modes of Operation The three modes of operation of the HCV are as follows 1 Fill Mode 2 Exhaust Mode 3 Dead Band Mode When the vehicle suspension is at the factory set ride height the valve will be in Dead Band Mode In Dead Band Mode the Valve will not allow air to flow in or o
12. 0 F 15 5 C and free from moisture dirt scale paint grease and other contaminates Pre heat per axle manufacturer 2 All welds must be performed in a flat or horizontal position Clean welds between each pass Standard Wire AWS ER 70S 6 0 045 DIA Volts 26 30 DCRP Current 275 325 AMPS Gas 90 AR 10 C02 at 30 to 35 CFH Note Brake camshaft to be located according to axle manufacturer specifications amp suspension trailer model Use locating fixture or flat surface to space suspension beams and center axle Check that suspension beams are parallel square to axle and perpendicular to axle e The suspension axle seat must be tight against the axle with no more that 063 gap at bottom Weld sequence size and weld direction should be followed for proper installation Back weld 75 over the start ends of all welds Fill all craters avoid cold laps and undercuts Place 1 tack welds in the center forward of both suspension beams 1 2 Position and weld rear root pass 3 4 After root weld hit tabs down for better 2nd pass Do not wrap welds over axle seat tabs no weld 13 from ends on 3rd passes Weld rear 2nd amp 3rd cover pass 5 6 8 Position amp weld front root pass 9 10 Weld front 2nd amp 3rd cover pass 11 12 13 14 Optional extra durability can be achieved by Hammer Peenning after welding use a 1 8 hardened ball end on weld and area Giving the World a Better Ride pw procs aw o October 10 2007
13. 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Inspection Schedule The following inspection schedule is a guide to help with the preventative maintenance of your Suspension system Your air suspension will provide many trouble free miles of service by using the information in this publication Original Inspection When reviewing the suspensions on your trailer for the first time check the following e The axles have been aligned properly e The suspension frame bracketry and air spring plate mountings have been properly supported The suspension ride height is set properly Trailer is level All welds are of good and acceptable quality All fasteners are in place and securely torqued No component interferences are visible No air spring air lines or shock absorber leaks are visible There should be 0 75 minimum clearance must be maintained around air spring when it is at maximum diameter e There should be 1 minimum clearance between top of tire and bottom of trailer structure when axle is at full jounce e There should be 2 minimum clearance between inside of tire and trailer frame structure for lateral movement e There should be ample fore and aft clearances Daily Inspection A quick visual inspection before operating the trailer will often detect obvious problems such as broken or loose parts 30 day Inspection Check clearances around all moving suspension parts such as air springs tires and shock absorbers for any
14. CUSH CORP suspensions amp Product Service Company Name Catalog Date Cush Corp 1001 Falconcrest Ct Nixa Mo 65714 Phone 417 724 1239 Fax 417 724 0126 www cushcorp com Pub P1203 01 Rev 6 October 10 2007 ad S j Giving the World a Better Ride Page 1 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL CUSH Suspension Systems service Manual Table of Contents Inspection Schedule Original Inspection Daily Inspection 30 day Inspection 90 day Inspection Axle Alignment Inspection Axle Inspection Post Inspection Notes Suspension Maintenance Items Caution Notes Trailer Lean or Dog Tracking Torque Specifications Customer Welding Notes Warranty Note Suspension Service Items Warranty Labor Allowances Axle Alignment Styles Shock Absorber Air Spring Chain Restraint Axle Attaching U Bolts Shear type Pivot Bolt Pivot Components Suspension Frame Hanger Welded type Suspension Frame Hanger Bolt on type Suspension Trailing Arms amp Axle H Beam OEM Reference WLA Height Control Valve Service Appendixes A Troubleshooting Guide B Service Parts Cross reference C Specific Service Bulletin Literature D Cush Trailer Suspension Parts Explosion Drawings Installation Procedures Appendixes S 11 Suspension to Axle Weld Procedures I2 Recommended Frame Welding Ref Drawing Giving the World a Better Ride Page 2 Pub P1203 01 Rev 6 October 10
15. EMS SERVICE MANUAL P1203 01 Appendix 11 Cush Suspension to Axle Welding Procedures RECOMMENDED STEEL WELDING PROCEDURES WARNING If these procedures and specifications are not followed damage to the axle or suspension could result The resulting axle or suspension damage could cause an accident property damage and or serious injury NOTE A welder qualified in 2G position per ANSI AWS D1 1 94 Section 5 Part C Welder Qualification must perform the welding NOTE The specification shown below is for horizontal 2F positioning 1 Suspension components and their mating parts must be at a minimum temperature of 60 F 15 5 C and free from moisture dirt scale paint grease and other contaminates Pre heat per axle manufacturer 2 All welds must be performed in a flat or horizontal position Clean welds between each pass Standard Wire AWS ER 70S 6 0 045 DIA Volts 26 30 DCRP Current 275 325 AMPS Gas 90 AR 10 C02 at 30 to 35 CFH lf these procedures and specifications are not followed damage to the axle or suspension could result The resulting axle or Suspension damage could cause an accident property damage and or serious injury NOTE A welder qualified in 2G position per ANSI AWS D1 1 94 Section 5 Part C Welder Qualification must perform the welding NOTE The specification shown below is for horizontal 2F positioning 1 Suspension components and their mating parts must be at a minimum temperature of 6
16. USH SUPENSIONS SYSTEMS SERVICE MANUAL Chain Restraint The chain restraint is a feature used to protect the shock absorber and air spring of your trailer suspension from overextension Without the chain restraint in place the suspension will function but damage can occur to the shock absorber Chain restraints are a replaceable item of an air Suspension and can extend the life of your shock absorbers and air springs To replace a chain restraint e Contact your trailer manufacturer or Cush Corp for replacement parts or cross reference Support the trailer in a safe manner prior to exhausting the air Exhaust all air from the air suspension system Remove the old chain restraint and attachment link Check the mounting surfaces for wear problems Check that the new chain restraint is the proper size and length to your old restraint Insert the new chain restraint Reconnect the attachment link checking that the chain is not bound up Supply air to the suspension system e Visibly check for any clearance issues with your new chain restraint Warranty Labor Allowance __0 1 hours each See the troubleshooting guide for more information on chain restraint issues U BOLT INSPECTION amp INSTALLATION NOTES CAUTION Do not apply any lubricants to the u bolts improper clamp loading can occur causing failure Inspection o Check each U bolt threaded area for damage or burrs o After installation an equal amount of thread should be visible beyond the h
17. air from the air suspension system Disassemble the pivot connection and any other parts that interfere with lowering the axle beam assembly out of the suspension hangers Lower the axle beam assembly check for any damaged beam wear Check that the wear washers are in usable condition Check that the bushing inserts are in usable condition Unbolt the frame hanger and discard the used fasteners Inspect trailer frame for damage Use new mounting hardware grade 8 and torque bolts to trailer mfg specification Mount new hanger component to trailer frame Raise the axle beam assembly to the hanger and reinstall beam Bolt hanger to frame per Cush Corp installation drawing Reassemble any other parts that were disassembled to lower axle beam assembly e Move the alignment gears to the nominal notch position and snug up hanger bolt e Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment e Torque all the fasteners to specification Warranty Labor Allowance __ 3 0 hours each or 5 0 hours axle See the troubleshooting guide for more information on frame hanger issues Suspension Trailing Arms amp Axle H Beam Cush manufactures various trailing arms for different applications because of this it would be best for you to contact Cush for an installation drawing per your application On these drawings we show recommended cross member and support locations Failure to have the proper support in place can cause a reoccurr
18. alve The ride height control valve HCV is used to carry and cushion the load of an air spring suspension Without an HCV in place damage can occur to the suspension or trailer If damaged HCV are a replaceable item and when maintained can extend the life of your air Suspension and trailer The HCV should maintain equal air spring heights for a set of grouped suspensions that are the same to maintain equal load carrying When the suspension is lowered from loading the HCV lever arm moves up and adds air to the Suspension air springs When the suspension is raised from unloading the HCV lever arm moves down and removes air from the suspension air springs in order to bring the arm back to neutral position The HCV is covered under the original OEM of the valve and this procedure is given as a guide only To replace a Height Control Valve e Contact your trailer manufacturer or Cush Corp for replacement parts or cross reference Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all air from the air suspension system Disconnect the air fittings from the HCV Remove the mounting hardware from the HCV and remove the HCV Insert the new HVC and appropriate mounting hardware Torque the fasteners to specification Reconnect the air fittings and air lines to the HCV Supply air to the suspension system Check for air leaks with soapy water Set the trailer at ride height by adjusting the HCV to allow air in or out Pin
19. ary Axle Inspection general notes see axle manufacture s service manual for details Visually inspect the seal and hub cap for leaks and oil level every 7 500 miles if oil bath type Repair if necessary At 100 000 miles or 12 months visually inspect seal and hub cap for contaminants oil level or leaks Check the wheel bearing adjustment Repair if necessary Post Inspection Notes lf issues arise from any inspection review troubleshooting guide Appendix A of this service manual If the issue can t be resolved from the troubleshooting guide or for warranty information contact your trailer manufacture If the problem is not related to installation the trailer manufacturer or suspension installer should contact Cush to resolve the issue or file the warranty claim Suspension Maintenance Items The Cush trailer air suspension system is designed to minimize service issues With proper maintenance the life of your suspension system can be extended Caution Notes e Trailer walk can occur due to loading unloading or loss of air spring pressure e For safe loading and unloading dump air spring pressure to lower vehicle e Do not tow or pull on vehicle by suspension components e Fasteners should never be reused over torqued or lubricated Do not operate vehicle suspension with e Broken welds or metal parts e Loose broken or missing fasteners or suspension components e Loss of air pressure in air springs or brake system Tra
20. d appropriate mounting hardware e Torque the fasteners to specification Warranty Labor Allowance 0 3 hours each See the troubleshooting guide for more information on shock absorber issues Air Spring The air spring is used to carry and cushion the load of an air spring suspension Without an air spring in place damage can occur to the suspension or trailer If damaged air springs are a replaceable item and when maintained can extend the life of your air Suspension and trailer Air Springs can also be used to lift the suspension observe the same safety precautions below when changing lift springs To replace an air spring e Contact your trailer manufacturer or Cush Corp for replacement parts or cross reference Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all air from the air Suspension system Disconnect the air fittings from the air spring Remove the mounting hardware from the air spring and remove the air spring Check the mounting surface for wear problems Insert the new air spring and appropriate mounting hardware Torque the fasteners to specification Reconnect the air fittings and air lines to the air spring Lower the trailer Supply air to the suspension system e Check for air leaks Warranty Labor Allowance 0 3 hours each See the troubleshooting guide for more information on air spring issues AU Giving the World a Better Ride Pub P1203 01 Fev 6 October 10 2007 C
21. ead of the nut on each side of the U bolt Installation o U Bolts should only be installed and torqued after completion of any axle welding Allow sufficient axle cooling time before applying torque to u bolts o Check that U bolts fit properly in area if U bolt is to tight tap on top of U bolt to hard surface to open up Be careful that U bolt installation does not damage threads o Snug all U bolts evenly before applying clamping torque with hand wrench Check that u bolts are parallel and square to axle o Torque U bolts in a three step process to avoid an improperly clamped axle and resulting damage Torque the u bolts in an X pattern with each torque step 1 2 3 4 This allows the U bolt to stretch and relax for the clamp to hold torque Proper tightening will allow equal amount of tread above each nut o Use a calibrated torque wrench to get the proper setting for the size of U bolt you are using o First Step 1 3 of Final torque Q 4 S d Step 2 3 of Final t x 7 o Second Step 2 3 of Final torque U BOLT NUT o Third Step Final torque x Lene SEQUENCE sg Pub P1203 01 Rev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Shear type Pivot Fastener Some Cush suspension models may offer a Shear type pivot fastener This Shear type bolt is well known in the heavy duty suspension market as being a fast and convenient way to apply the proper torque The same installation tooling can be used with
22. en notified then a Warranty Labor Allowance may be needed The WLA for the following service items are shown with each itemized description The service item descriptions include the obvious parts involved other parts may be involved to complete the warranty repair Shop per hour labor rate allowances will not exceed standard industry averages for the work done Warranty claims should be filed per the Cush Corp Warranty publication PO202 01 with an itemized list of charges and copies of all available receipts AUS Giving the World a Better Ride Pub P1209 01 Fev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Suspension Service Items Axle Alignment Cush has several different alignment means available for different applications Listed here are some general alignment guidelines and alignment procedures for the styles of Cush Alignment CAUTION DO NOT APPLY undercoating to the Cush Align area until after alignment and torque of the suspension pivot bolts Check that the tire inflation pressure is correct on all tires Alignment should be performed with the vehicle empty and the brakes released On a level floor move the vehicle forward and back to straighten make sure last movement is forward Remove the outer tires and any other parts from under the chassis that obstruct the measuring distances between the kingpin and the axle ends If you use a commercially available kingpin and axle spindle extenders
23. equire wheel drum or hub removal 1 0 Includes e Removal and installation of Cam tube weld re weld Slack adjuster e Brake adjustment IUS Giving the World a Better Ride Pub P1200 09 Fev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Wheel end tire and wheel removal and installation Inner wheel seal 1 0 Hub 1 4 Wheel studs up to three 1 Hub cap gasket 0 5 Includes troubleshooting Troubleshooting Guide P1203 01 Appendix A Contact Cush Use this guide to review possible suspension maintenance and service issues possible causes of issues and possible solutions Contact Cush Corp before cutting or welding on any suspension components that could void your warranty Service Parts Cross reference Guide P1203 01 Appendix B Contact Cush Use this guide to review possible Cush suspension service parts cross referenced to competitive part numbers that might be more readily available to you Specific Service Bulletin Literature P1203 01 Appendix C Contact Cush If deemed necessary by Cush Corp we will publish a service bulletin specific to a certain Suspension application issue Contact Cush Corp to see if there is a service bulletin that might help with your specific service situation Cush Suspension Parts Explosion Drawings Drawings may vary per your application Contact Cush for drawings Giving the World a Better Ride pw procs October 10 2007 CUSH SUPENSIONS SYST
24. g Keeper Bolt amp Nut 1 2 13 UNC 5 B 65 75 88 102 TRAC ALIGN Rack Lock Bolt 13 UNC 5B 25 35 34 47 10K U Bolt Nut 11 UNC 8c 180 210 244 285 Brake Chamber Mounting Nut 5 8 141 UNC 5 B 100 110 136 149 Nyloc Jam Nut 3 4 10 UNC AB 80 100 108 136 Shock Mount Nut Bolt 10 UNC 5 8 210 235 285 319 CAP Spring Pivot Bolt amp Nut 10 UNC 8 C 330 380 447 515 15K U Bolt Nut 3 4 10 UNC 8 C 330 380 447 515 25K U Bolt Nut 7 8 14UNF 98 C 475 525 644 712 Pivot Nut SecureLok Securex 7 8 14 UNF 8 C 550 600 746 813 Page 5 Giving the World a Better Ride Pub 1203 01 Fev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Customer Welding Notes e Itis the responsibility of the suspension installer and vehicle designer to provide adequate vehicle frame design gusset support in the area of Suspension attachment and proper securing method for the suspension system The suspension installer has the responsibility to determine the proper welding parameters for the materials being used For specifications of suspension component materials contact Cush e Required cross member locations are shown Actual size and shape may vary per trailer design It is the responsibility of the suspension installer to ensure structural adequacy of the trailer frame and related cross members e No welding of any of the suspension components is permitted except
25. h Align to be tight enough to hold the joint together but loose enough to permit use of the alignment gear e Set the alignment gear indicator tab at 6 o clock the neutral position This gives you pivot movement fore and aft Be sure that there is one tooth of the gear washer outside of the hanger rack both sides to be at the middle of the hanger slot see Figure 1 ONE GEAR TOOTH OUTSIDE OF RACK EACH SIDE FOR NOMINAL POSITION 7 PIVOT FORWARD 172 FROM NOMINAL PIVOT REARWARD 41 2 FROM NOMINAL Figure 1 e To align the axle rotate the alignment gear of one side of the suspension to get the axle aligned If needed go to the other side of the suspension and rotate the alignment gear in the opposite direction to fully align the axle As standard there are two alignment gears per hanger Use the gear on the outside of the hanger to set the alignment and the inside gear for fine tuning of the alignment NOTE Before tightening the pivot connection fasteners be sure that the spacer collars are against the bushing inner metal and hanger side Failure to follow these procedures and or properly torque the pivot fasteners at this time can result in a failed pivot connection and a loss of warranty coverage WARNING After alignment clamp the joint per Cush bolt nut torque specifications After alignment the suspension installer can weld the gear washer to the hanger side with 1 2 welds both sides of washer to prevent tam
26. he air bags to adjust to approximate ride height Then put the handle in the horizontal position 2 Install wood Centering Pin in hole provided in valve handle 3 Connect linkage from suspension mount to valve handle and tighten linkage 4 Adjust to final factory recommended ride height by rotating the valve assembly on the bracket 5 Tighten nuts to 45 Inch pounds torque 6 Remove the centering pin Giving the World a Better Ride pw eras aove October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Warranty Labor Allowances hours each Air reservoir 1 0 Brake chamber 0 8 Brake hose relay valve to brake chamber 0 5 Quick release valve Height control valve 1 Includes e Removal and installation of height control valve and the linkage e Ride height adjustment at linkage Height control valve linkage__0 5 Solenoid valve 1 0 Air pilot valve 1 0 Brake protection valve 1 0 O 0 Flipper valve 1 0 Hand control valve 1 0 Manual exhaust valve 1 0 ABS wheel sensor one 1 0 Includes e Removal and installation of Tire and wheel assembly Brake drum Adjust ABS wheel sensors up to four 0 5 ABS relay valve__ 1 0 ABS modulator valve 1 1 ABS electronic control unit ECU 1 1 Slack adjuster 0 7 Brake camshatt Does not require hub removal 1 2 Includes e Removal and installation of Tire wheel assembly Slack adjuster e Brake adjustment Brake cam tube assembly Does not r
27. iler Lean or Dog Tracking lf your trailer is having problems with Lean or Dog Tracking please refer to the Troubleshooting guide in Appendix A of this manual AU S Giving the World a Better Ride TE October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Torque Specifications It is the customer s responsibility to check and tighten fasteners to specified torque at installation after the suspension has been in operation for 3000 miles and at Suspension inspection cycles Failure to do so can result in loss of warranty e Torque values given are specified for the fasteners in the condition supplied by Cush Corporation e DO NOT APPLY ANY ADDITIONAL LUBRICANTS e CAUTION Fasteners should never be reused if removed or loss of clamp load occurs For proper joint clamping contact Cush for replacement fasteners or use fasteners of equal strength e CAUTION Over torquing fasteners could result in material failure Common Torque Specifications See Cush Safety and Inspection Sticker on your trailer AIR SPRING PROVIDED MOUNTINGS MAX SIZE Threaded Studs ft lbs 3 8 24 UNF STUD 20 3 8 16 UNC BLIND NUT 25 1 2 13 UNC STUD 25 1 2 13 UNC BLIND NUT 50 3 4 16 UNF COMBO STUD 50 Air Ports 1 4 18 NPTF AIR FITTING 1 1 2 14 NPTE AIR FITTING 23 tts vy General Fastener Torque Specs Size Thread Grade Min Max Min Max Sprin
28. ing failure mode Contact Cush to see if it is required to replace the trailing arm or the H Beam of the suspension please follow the guidelines below as a minimum safety procedure when repairing these items Suspension H Beam To replace the suspension H Beam Beam only axle replacement with a pair of trailing arms e Contact your trailer manufacture or Cush Corp for replacement parts and installation drawings On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all air from the air suspension system Remove the Brake chambers leave the air lines attached Remove the Slack adjusters and mounting hardware shims and pins Remove the ABS valves and sensor wiring from the H Beam Remove the air spring connections to the H beam Remove the shocks and mounting hardware from H Beam Remove the Height control valve connection to the H Beam J Giving the World a Better Ride sw eras ave October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL e Disassemble the pivot connection and any other parts that interfere with removing the H Beam assembly from the suspension hangers and from the trailer frame e Lower the axle beam assembly or lift the trailer to drop the H Beam e Check for any damaged hanger wear e Remove the axle assembly from under the trailer e Remove the tires wheels and proceed to strip axle e Remove the
29. l Rate bushing and inside of trailing arm bushing sleeve with proper rubber lubricant P 80 or Ru glyde e Orient voids in bushing within 5 degrees plus or minus of vertical position when suspension is in operation e Center inner metal bushing in sleeve with the outer metal bushing housing with tool it may be necessary to push bushing thru a little and pull back to center rubber and inner metal sleeve Reassembling pivot connection Frame Hanger style e Position wear washers over the outside diameter of the bushing tube Some models Install the flanged inserts in the inner diameter of the bushing tube Place the pivot bolt through the partial assembly Hand tighten a non locking nut to hold the position of all loose items Using a hydraulic jack or other lifting device raise pivot end of trailing arm until flanges of flanged inserts enter the inside of the hanger e Holding this raised position remove pivot bolt and standard hex nut continue to raise pivot end of trailing arm until hole in bushing lines up with slots in hanger e Place adjustment gear on pivot bolt per suspension drawing Always use new fastener hardware October 10 2007 USH Giving the World a Better Ride Pub P1203 01 Fev 6 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Re insert pivot bolt through side of hanger or yoke beam engaging all teeth of the alignment gear as shown in Figure 1 Note one gear tooth outside of alignment rack both sides for neu
30. olt head should be installed from the outboard side o NOTE Check for any flashing or obstructions to cause the bearing washers to be raised and not allow flush mounting against the hanger sides gear or eccentric type o Check proper axle alignment see installation manual for instructions on alignment o Snug the pivot fasteners so that the alignment washers do not move while applying initial torque recheck alignment o Torque the shear type pivot bolt with the E 20 Torx drive socket tool until the bolts Torx head shears off o The E 20 Torx drive socket should fully engage the Torx shear head before and while applying torque o Apply paint to the sheared away Torx area as a rust preventative Warning It is the responsibility of the assembler OEM Dealer Repair Facility etc to inspect and insure proper installation of the Shear type bolt If improperly torqued the pivot clamp force can fail resulting in unreliable axle alignment vehicle instability personal injury and or property damage Socket Description Drive Size Cush Hendrickson Camcar Apex E 20 Torx Socket Heavy Duty 1 Square V 24536 A 24536 TX 8120 E 20 p E 20 Torx Socket Heavy Duty w Sleeve 1 Square V 25119 A 25119 age 14 01 Rev 6 LJ October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Pivot Components The pivot of a trailing arm air ride suspension is the main link to connect the suspension to your t
31. ours axle See the troubleshooting guide for more information on pivot connection issues Pivot Wear Washer The pivot wear washer is used to prevent metal to metal contact of the suspension beam and the inside of the hanger These wear washers can cup and misshape and still function At the point the wear washer is worn thru they should be replaced to prolong the life of the suspension To replace wear washers e Contact your trailer manufacturer or Cush Corp for replacement parts or cross reference On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all air from the air suspension system Disassemble the pivot connection and any other parts that interfere with lowering the axle beam assembly out of the suspension hangers Lower the axle beam assembly check for any damaging hanger wear Remove the flanged inserts from the inner diameter of the bushing tube Remove the old wear washers Check for any damaging beam hanger or insert wear Insert the new wear washers and appropriate flanged inserts Place a pivot bolt through the partial assembly S Giving the World a Better Ride a gr Po 8 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL e Hand tighten a standard hex nut to hold the position of all loose items e Raise the axle beam assembly and reassemble the pivot connection use new pivot bolts amp
32. pering amp for off road applications we recommend for abusive applications AU Giving the World a Better Ride Pub P120 01 tev 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Alignment Style 2 Cush Align Il Econo 3 4 alignment 1 2 thk gears The Cush Align II pivot joint features outside gear tooth washers that cover the alignment slot and mate with a grounded rack plate After alignment clamp the joint per Cush torque specifications After alignment the suspension installer can weld the gear washer to the hanger side with 1 2 welds both sides of washer to prevent tampering amp for off road applications e f realigning the gear washer may be welded to the side of the hanger grind the welds loose without gouging the side of the hanger Remove the gear washers and clean away weld material e Snug the bolts of the Cush Align to be tight enough to hold the joint together but loose enough to permit use of the alignment gear e Set the alignment gear indicator tab at 6 o clock the neutral position This gives you pivot movement fore and aft Be sure that there is one tooth of the gear washer outside of the hanger rack both sides to be at the middle of the hanger Slot CUSH ALIGN Pivot amp AudiTorx Fiqure 2 e Toalign the axle rotate the alignment gear of one side of the suspension to get the axle aligned If needed go to the other side of the suspension and rotate
33. railer This link provides a resilient connection that allows an axle to walk without excessive flexing Re bushing of a suspension requires the use of a bushing removal installation tool and bushing kit containing the required components for re bushing Contact Cush for information regarding the tool and the proper kit for your suspension and review any instructions on your Suspension drawing Disassembling Pivot Connection e On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height prior to exhausting the air Exhaust all air from the air suspension system Loosen and remove shock connection and chain restraint Loosen and remove any jam nut Loosen and remove pivot nut Remove Pivot bolt and alignment gears Disassemble any other parts that interfere with lowering the trailing arm axle assembly out of the suspension hangers e Using a hydraulic jack or other lifting device lower pivot end of trailing arm axle from inside hanger Yoke suspensions will need to be pulled out from trailer frame Bushing Replacement Frame Hanger style Use Cush bushing replacement kit shown on parts explosion for your suspension or contact Cush Corp for cross reference Some models remove the flanged inserts from the inner diameter of the bushing tube e Remove old bushing using bushing tool e Clean inside surface of trailing arm bushing sleeve e Lubricate outside of new Cush Dua
34. rts explosion for your Suspension or contact Cush Corp for cross reference Reassembling pivot connection Frame Yoke style Insert new bushing with metal sleeve and orient voids in bushing within 5 degrees plus or minus of vertical position compared to the trailer frame See and mark bushing housing for vertical inspection once washers cover voids orientation can not be seen Cush marks bushing front with notch Position wear washers over the outside diameter of the bushing inner tube Install the flanged insert spacers in the inner diameter of the bushing inner tube both sides Place a pivot bolt through the partial assembly Hand tighten a non locking nut to hold the position of all loose items Adjust the new bushing with sleeve in trailer frame sleeve per recorded information so you can get the yoke beams and axle assembly started onto the bushings flanged spacers Do not weld until after axle assembly is centered Using a hydraulic jack or other lifting device raise pivot end of yoke trailing arm until flanges of flanged inserts enter the inside of the yoke suspension beam Holding this raised position remove pivot bolt and standard hex nut continue to raise pivot end of trailing arm until hole in bushing lines up with slots in yoke beam Giving the World a Better Ride pw eras avo October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL e Place adjustment gear on pivot bolt per suspension drawing Always
35. the alignment gear in the opposite direction to fully align the axle As standard there are two alignment gears per hanger Use the gear on the outside of the hanger to set the alignment and the inside gear for fine tuning of the alignment WARNING After alignment clamp the joint per Cush bolt nut torque specifications After alignment the suspension installer can weld the gear washer to the hanger side with 1 2 welds both sides of washer to prevent tampering amp for off road applications we recommend for abusive applications AU Giving the World a Better Ride puw praostos Ses 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Alignment Style 3 Trac Align 3 4 alignment 1 2 thk eccentric optional locking rack The Trac Align was designed to give our customers extra pivot integrity with the addition of the optional locking rack and a more familiar alignment means with the use of an eccentric cam adjustment The Trac Align also has bearing washer with tabs for use with a Cush axle welding stand to have a more precise fixturing of the suspension and axle at factory or customer integration Please note that the tabs on the inner bearing washer can be in any position after installation as they do not indicate pivot alignment After alignment clamp the joint per Cush torque specifications After alignment the suspension installer can weld the outside washer to the hanger side with
36. tral position Place adjustment gear on end of pivot bolt against inner face of hanger engaging all teeth of the alignment gear as shown in Figure 1 Note one gear tooth outside of hanger rack both sides for neutral position Place pivot nut on end of pivot bolt and tighten until snug to hold tooth engagement of alignment gears Using a wrench move alignment gear pointers to nominal position Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment Reinstall shock absorbers and chain restraints Torque all the fasteners to specification Warranty Labor Allowance__ 5 0 hours axle See the troubleshooting guide for more information on pivot connection issues Bushing Replacement Frame Yoke style After removing the yoke style trailing arm axle from the bushing frame area record how much offset each bushing side is to the trailer frame outer bushing metal sleeve The Yoke style bushing can be replaced with the bushing tool but it is usually easier to replace the inner bushing and metal sleeve housing by removing the small welds that connect the inner bushing housing to the frame sleeve housing suspension drawing Grind or torch the welds of the inner to outer housing without damaging the outer frame housing tube Remove old bushing and metal housing from trailer frame and clean the outer frame housing tube for reuse Inspect trailer frame flange for damage Use Cush bushing replacement kit shown on pa
37. use new fastener hardware e Re insert pivot bolt through side of yoke beam engaging all teeth of the alignment gear as shown in Figure 1 Note one gear tooth outside of alignment rack both sides for neutral position e Place adjustment gear on end of pivot bolt against inner face of yoke beam engaging all teeth of the alignment gear as shown in Figure 1 Note one gear tooth outside of rack both sides for neutral position e Place pivot nut on end of pivot bolt and tighten until snug to hold tooth engagement of alignment gears e Using a wrench move alignment gear pointers to nominal position and snug nut bolt assembly e Axle assembly with yoke beams need to be centered on trailer frame and aligned with other trailer tires outside position e Once axle has been positioned side to side on trailer frame recheck that bushing voids are in vertical position and weld bushing inner metal sleeve to trailer frame bushing housing sleeve with 1 2 min welds 4 places around both sides of sleeve each e Do not worry about minor melting of plastic wear washer do not catch washer or bushing on fire e Stagger the sequence of welding as to allow adequate cooling between welds to prevent excessive heating of the bushing e Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment e Reinstall any shock absorbers and chain restraints e Torque all the fasteners to Cush specification Warranty Labor Allowance__ 5 0 h
38. ut of the air bags As the vehicle becomes laden the suspension will settle causing the handle of the valve to rotate upwards The valve will now enter Fill Mode allowing air to enter the air bags causing the vehicle to rise As the vehicle approaches factory set ride height the valve will once again enter Dead Band Mode Similarly if the bus is unloaded the Suspension will rise causing the control handle of the valve to rotate downward When the handle rotates downward the valve enters exhaust mode thereby letting air out of the air bags causing the vehicle to lower until Dead Band Mode is reached again at the factory set ride height Installation Attach all fittings to valve before mounting to vehicle Thread sealant must be applied to all fittings which are tightened by hand until firm at which point a wrench should be used to tighten additional 1 1 1 2 turns Recommended proper orientation for the valve handle for installation is when the valve handle is in line with the C1 port Mount the Valve to a bracket using the 14 studs Do not fully tighten nuts at this time to allow fine tune adjustment of ride height Attach Air Supply line to the port at the top of the valve Attach the air bag air lines to the C1 and C2 ports Set U 1 Adjust approximate ride height by turning the valve handle up toward the air supply line to add air to the bags to raise the vehicle above the ride height down to exhaust air from t
39. wheel nuts drums spindle nut and hubs from the axle e Remove bearings and seals from the axle e Remove the brake lining shoes and springs from the axle e Remove the bushing inserts and wear washers from bushing reuse if necessary e Install the new H Beam assembly from Cush Corp e Reinstall the axle components and then roll the axle assembly under the trailer e Raise the H Beam lower the trailer to working height and reassemble the pivot connection e Hook up all air lines and check for leaks e Reassemble any other parts that were disassembled to lower axle beam assembly e Move the alignment gears to the nominal notch position and snug up hanger bolt e Align axle with relation to the kingpin as shown in Figure 2 see Axle Alignment e Torque all the fasteners to specification e Package the damaged H Beam assembly for shipment to Cush Corp contact Cush for pick up Warranty Labor Allowance _ 8 0 hours H Beam Giving the World a Better Ride sw eras aov 6 October 10 2007 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Original Equipment Manufacturer s Warranty Reference WLA Warranty for the following non exclusive list of parts if supplied by Cush will default to the Manufacturer s Warranty and no labor to repair or replace these parts unless allowed If damage to these parts is caused by a defect from a Cush Corp product then use these WLA as a guide when filing an approved warranty claim Ride Height Control V
40. where specified by Cush e Any alteration of the suspension components or installation deviations must be approved in writing by Cush Corporation Recommended Steel Welding Procedures If Required e WARNING If these procedures and specifications are not followed damage to the axle or Suspension could result The resulting axle or suspension damage could cause an accident property damage and or serious injury e A welder qualified in 2G positions per ANSI AWS D1 1 94 Section 5 Part C Welder Qualification must perform the welding e The specification shown below is for horizontal 2F positioning e Suspension components and their mating parts must be at a minimum temperature of 60 F 15 5 C and free from moisture dirt scale paint grease and other contaminates e All welds must be performed in a flat or horizontal position Achieve spray arc transfer with the following welding parameters e Standard Electrode AWS E 7018 Oven Dried 0 125 DIA 120 140 AMPS D C Electrode positive Standard Wire AWS ER 70S 6 or AWS ER 70S 3 0 045 DIA Volts 26 30 DCRP Current 275 325 AMPS Wire Feed Speed 380 420 Inches per Minute Electrode Extension 0 75 to 1 Gas 86 AR 14 C02 at 30 to 35 CFH Any deviation from these welding parameters must be of equal strength or approved by Cush Corporation in writing Warranty Note lf after review of the Cush Corp Warranty it is determined that there is a warranty issue and Cush Corp has be
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