Service Manual PDF
Contents
1. Bushing Replacement Use Cush Bushing replacement kit shown on parts explosion for your suspension or contact Cush Com for cross reference Lubricate outside of new Cush bushing and inside of spring eye bushing sleeve with propor rubber lubricant P 80 or Ru Put bushing into bushing insertion tool o reduce bushing from tree OD to smaller of spring oye Lubricate too before placing bushing Press in bushing ry to center inner metal bushing sleeve with the outer metal bushing housing it may be necessary to push bushing thru a and pull back to cantor rubber and inner metal sleeve Reassembling pivot connection lf required replace the flanged inserts from to the inner diameter of the bushing ube sleeve if these inserts are loose and do not stay place you may need to hold these inserts while guiding the spring nto the compensator walking beam hanger CLSH Giving the World a Better Ride tt CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Note itis easier to do this with the compensator on the ground upside down and use gravity to lower the spring eyes into the compensator Center the spring eye with inserts at the compensator pivot slot use a tapered rod to assist Gather tho alignment gear hardware and new fasteners to remount the pivot Hand tighten the pivot hardware to hold the postion of loose items I needed to spread the compensator hanger using a hydraulic jac2. The suspension axle seat must be tight against the axe TRO ube with no more that 063 gap at bottom Weld sequence size and weld direction should be followed for proper instalation Back weld 38 over the slarvends of all welds Fil al craters avoid cold laps and undercuts Place 1 2 tack welds inthe conter forward of both suspension ale seats Position and weld rear root pass Do not wrap welds over axle seat ends weld 197 from ends Weld rear 2nd amp 3rd cover pass Position amp weld ron root pass Weld front 2nd amp 3rd cover pass Weld seat side welds Note Move back and allow welds to cool and minimize distortion You can skip in a X pattern for the axle welding USH Giving the World a Bett CUSH SUPENSIONS SYSTEMS SERVICE MANUAL U BOLT INSPECTION amp INSTALLATION NOTES CAUTION Do nat apply any addtional lubricants to the u bolts improper camp loading can occur causing failure Inspection Check each threaded area or damage or burrs Alte installation an equal amount of thread shouid visible beyond the head of ha nut each side of he Installation U Bols should only be installed and torqued after completion of any axe welding Allow sufficient axle cooling tme before applying torque to u bol Check that U bolts i properly in area U bolt is ta tap on top of to hard surface to open up Be ea
3. 5 OD 0405 Trunion Bolt w Nuts zi TGS TGS UNG xT ge 4 Nut 1257 7UNG Lock 3 Pivot Bushing Kit Per Spring Eye ES HHCS 05TH SUNCYTS 818 1 Nu SacureLok Nut 087579 UNG 1 d Busing inser 25 Spacer amp Reducer 1 125 OD 0910 Con SeBushing 112810 x 33279 x 3 257 housing 24500 Free Rubber 31 Irac Align Pivot Alignment Kit Per Spring Eye 0338 ES IZ T Alignment Gear wiSauare Oui i a Round Aigrment Gear FitureBesrng Pate lane 1i ho Ki Keeper Sleeve Eg Gri 31 To Tut 0 75 0 UNG grd C ma l 10 THD Kasper Sieve 1380D 811014418 Tsaa 0 wiNuts amp Washers Tal UBol 76 TUNE x5 Round x 15g Gg 1 Tj Nui 78 14 UNE nd Washer 0 875 SAE Had Ha a Spring 4 leaf 50K style with eye 78th C0 Page 17 CLSH Giving the World a Better Ride CUSH SUPENSIONS SYSTEMS SERVICE MANUAL 5 Giving the World a Better Ride set
4. Reference a typical installation of cams in the picture below c Note Customers must check that camislack placement will not cause interference with trailer components causing part failures SH Giving the World a Better Ride meo CUSH SU fiant ot Cush Suspension to Axle Welding Procedures RECOMMENDED STEEL WELDING PROCEDURES WARNING I these procedures and specications are nt followed damage to the axie or Suspension could result The resulting or suspension damage coud cause an accident property damage andlor serious injury NOTE A welder qualified in 2G positon per ANSUAWS 1 1 98 Section 5 Part Welder Guaticaton must perform the welding NOTE The specication shown below s for horizontal 2F positioning 1 Suspension components and their mating paris must be a a minimum temperature of 60F 15 5 C and re rom moisture dirn scale paint grease and ater contaminates Pre heat axie manufacture 2 Al welds must performed in a fat or horizontal postion Clean welds between each pass Standard Wire AWS ER 705 6 0 045 D1A Vols 26 30 DAP Current 275 325 AMPS 101002 at 30 o 35 CFH Note Brake camshatt to be located according to axle manufacturer specications amp suspension raler model Use locating fixture or surface to space suspension axle seals and centar axle Check that axle seats are parallel square te axo and perpendicular to
5. of the Suspension installer to instal guides to support the appropriate load Your application Contact Cush with questions about lateral suppor guides USH Word a Better Fidel CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Inspection Schedule Tne folowing inspection schedule is a guide o help with the preventative maintenance of your suspension system Your mechanical suspension will provide many trouble free miles of service by using the information in this publication QC CushFLEX Hanger Pre Welding amp Alignment Verify that you have the correct height and width straddle mount hangers for your application It will be easier to mount the straddle mount hanger if you first remove all mounted components from the hanger set Before welding the suspension straddle mount trunion hanger to the frame you need to first measure that the center of the trunion tube is aligned to the kingpin of the trailer Measure to the outer vertical hanger ear and to the trunion tube Also verify that the trunion hanger is centered on the frame Note the straddle mount trunion tube may not be centered on the hanger ears and this is why it is best to measure to the hanger ears Measure from outside of vertical ear L1 both sides to get trunion aligned to trailer QC CushFLEX Original Inspection After Installation When reviewing the suspensions on your trailer fo
6. CUSH CORP Mechanical Suspension Model CushFLEX CSP CF Tandem Axle Independent Cantilever Springs With Straddle Mount Hanger Suspension Installation amp Product Service 50 000 68 Rating 59 Axle Spacing Shown Table of Contents Model Specific Service and Installation Manual Cush Model CushFLEX Description Installer Responsibility Inspection Schedule Hanger Pre welding Original Inspection Daily Inspection 30 amp 90 day Inspection Axle Alignment Inspection Axle Inspection Suspension Maintenance Items Caution Notes Torque Specifications Customer Welding Notes Warranty Note Suspension Service Items Axle Alignment Axle Seat Welding Pivot Components Suspension Trunion Straddle Mount Hanger Service Appendixes Suspension Parts Explosion Drawing Typ Application Drawing 1001 USH Giving the World a Better Ride ant CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Model CushFLEX CSP CF Description This model is designed to work with 4 wide Cantilever bushing eyed springs Independent cantilever springs allow more suspension articulation and a better ride than rigid walking beam or spring leat walking beam single point suspension These springs are rated per suspension capacity The CushFLEX model is designed to have several advantage features over competitive units Track Align adjustment on the axle heavy duly hanger and rocker component
7. e 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 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 see Cush Axle Alignment procedures in this manual Align the next axle to within 0 063 tolerance amp any additional axles to the forward axle per the proper alignment method Use a commercially available alignment gauge or trammel bar if available seo Figure 2 a BY E KINGPIN e ANH Bg FRO Figure 2 NOTE Failure to follow the procedure for your axle alignment application andior properly torque the pivot fasteners can result in a failed pivot connection and a loss of warranty coverage USH Giving the World a Better Ride ET uH CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Cush Alignment on CushFLEX Trac Align 1 2 alignment adjustment amp optional locking rack The Trao Align was designed to give our customers extra pivot integrity
8. gned to minimize service issues With proper maintonanco he Ife of your suspension system can be extended Caution Notes Traller walk can occur due to loading unloading or damaged parts For sate loading and unloading leave aor attached to vehicle Do not tow or pull on vehicle by suspension components Fasteners that have been inservice should never bo reused over torqued or lubricated Do not operate vehicle suspension with gt Broken welds or metal parts 7 Loose broken or missing fasteners or suspension components 1 of air pressure in brake system USH Giving the World a Better Ride TH CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Torque Specifications Itis 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 CUSTOMER TORQUE INSTRUCTIONS 2 tis the customers responsibilty 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 3 Torque values given are specified forthe fasteners in the condition supplied by Cush Corporation DO NOT APPLY ANY ADDITIONAL LUBRICANTS 4 CAUTION Fasteners should never be reused removed or complete loss of clamp load occurs For p
9. k or other spreading device spread open the compensator until flanges of flanged inserts enter the inside of the compensator remove spreading device Place adjustment gear per suspension drawing Always use new fastener hardware Using a wrench move alignment gear pointers to nominal position Align axle with relation to the kingpin per Axle Alignment notes Torque all the fasteners to specification Suspension Trunion Straddle Mount Frame Hanger Cush manufactures various hangers far different applications because of this it would best for you to contact Cush for an installation drawing per your application On these drawings we may show recommended cross member and support locations your trailer manufacture may have an installation drawing for this Failure to have the proper support in place can cause reoccurring failure mode If for some reason itis required replace a frame hanger please follow the guidelines below as a minimum safety procedure when repairing these items To replace welded frame hanger SH Giving the World a Better Ride Contact your trailer manufacturer ar Cush Corp for replacement parts On level ground securely chock the ies and apply trailer parking brakes Support the trailer in a safe manner at a working height Remove Ties as required Disassemble the pivot connection and any other parts that interfere with lowering the walking beam out of the suspension hanger Lower the assembly check fo
10. onsibilty of the suspension installer to ensure structural adequacy of the trailer frame and related cross members No welding of any of the suspension components is permitted except where specified by Cush alteration of the suspension components or installation deviations must be approved in writing by Corporation Recommended Steel Welding Procedures If Required WARNING I these procedures and specifications are not followed damage tothe axle suspension could result The resulting axle or suspension damage could cause accident property damage andor serous injury A welder qualified in 2G positions per ANSUAWS D1 1 94 Section 5 Part Welder Qualiticalon must perform the welding The specification below i for horizontal 2F positioning Suspension components and their parts must be ata minimum temperature of 60 155 and fro rom moisture dir scale paint grease and ather contaminates lt welds must be performed in a fat horizontal position Achieve spray arc iranster with the following welding parameters lt Standard Electrode AWS 7018 Oven Dried 012510 120 140 AMPS D C Electrode positive Standard Wire AWS ER 70S 6 or AWS 708 3 0 045 DIA Vols 26 30 DCRP Current 275 325 AMPS Wire Feed Speed 380 420 Inches per Minute Electrode Extension 0 75 lo 17 Gas 86 AR 14 at 30 o 35 Any deviation from these welding parameters m
11. r any damaged or wear Check that the bushings are in usable condition Mark the hanger position on the frame sido for reference Cut away the frame hanger and clean up the frame with grinder do not gouge frame Raise the new hanger assembly to the frame and clamp hanger to frame squarely Align hanger assembly to kingpin see Hanger Alignment notes Weld hanger to trame per Cush Corp installation drawing Reassemble any other pars that were disassembled to lower assembly Align axles with relation to the kingpin see Axle Alignment Torque all the fasteners to specification Apply paint to prevent rust corrosion 15 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Figure 4 Exploded View CSP 50CF 512 43 Capacity 50 000 Ibs Ride Height 12 Centers 43 USH Giving the World a Better Ride Pa prod CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Table 4 for Figure 4 CSP 50CF S12 43 Parts List Mem Description CSP SOCF S12 43 Number ay iompensalor Assembly tor 59 Axle Spacing wosez eld on Axle Spring seat for 5 round osa on Bottom Spring seat w dowel lwosso Mount Trunion Hanger w 4 tube for 43 BC Wo6e3 1243 Irrunion Bushing Cap Hutch Style 898 00 coao2 Ja Rubber Trunion Bushing 9 125 tg x 18 x S OD ke ethane Trunion Bushing 92125715 x 18 x
12. r the gear For adjustment use a breaker bar in the Ys square hole The CushFLEX Trac Align gives you 1 4 pivot movement tore and aft per pivot To align the rotata the alignment gear of ane side of the suspension to get the axle aligned I needed go to the other of Ine suspension and rotate Ine alignment gear inthe opposite drection la luly align tha axi SH Giving the World a Better Ride EIN ad CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Axle Spacing Cush has several different axle spacing s available for differant applications See your Cush installation drawing for your application zs E Q ADJUSTMENT 78 AXLE SPACING NOTE Tho axle spacing wil be measured with the trailer unloaded The axle spacing and ride height will decrease as the suspension springs are loaded and defect up Axle Welding Installation Notes Customers may have different axle tracks and applications that wil dictate the center spring beam spacing to mount the axle seat to the axi c Spring seats may be pre wolded to axles prior to assembling to other suspension components see Cush installation drawings Note cam shaft Clocking for welding axles 43 Beam Centers Shown c Customers should also determine the clocking of the cam relative to the suspension axle seat Customers may want to vary this per their application
13. r tho first tima check the following gt The axles have been aligned properly The suspension frame bracketry have been properly supported Trailer is level Al welds are of good and acceptable quality Al fasteners are in place and securely torqued No component interferences are visible There should be 1 minimum clearance between top of tire and bottom of trailer structure when axle is at full jounce not a bump stop will need to be added There should be 2 minimum clearance between inside of re and trailer frame structure for lateral movement There should be ample fore and aft clearances SH Giving the World a Better Ride Page CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Daily Inspection A quick visual inspection before operating the trailer will often detect obvious problems Such as broken or loose paris CushFLEX 30 day Inspection Check clearances around all moving suspension parts such as springs tires axle seats irbolis fasteners and compensator for any signs of wear loosening or component interferences Check each af the following Fasteners Not loose broken or missing relorque needed Pivot Bushings Not protruding off center torn or worn Frame Hangers Not worn cracked bent or damaged Compensator Not worn cracked bent or broken Cantilever Springs Not cracked bent out of alignment or loose Axle Beam Not cracked bent or broken Tiros No tire
14. rful that U bol installation does damage threads Snug U bolts evenly betore applying clamping torque with hand wrench Check that u bolls parallel and square o axe c Torque U boltsin a three step process to avoid an improperly clamped axle and resulting damage Torque the in an 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 alow equal amount of tread above each nut Use a calibrated torque wrench to get the proper setting forthe size of U bolt you are using a I First Step 1 3 of Final Second siep 2 ol Final Torque N id Siep Fia torque MED NUT o AS Ater bots have been torqued spec weld bottom pte gussets sides to side of spring end box to secure that cantilever springs do not delaminato Use 4 Tong welds SH Giving the World a Better Ride CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Trunion Pivot Component Replacement The pivot of a trunion hanger on a mechanical suspension is the main link to connect the suspension to your trailer This ink provides resilient connection that alows a walking beam or compensator to walk without excessive flexing Re bushing of a straddle mount hanger suspension does not require a shop press You must remove the waking beam and cap to get fo the trunion bushing Disassembling Pivot Connection of an under slung
15. roper joint clamping contact Cush for replacement fasteners 5 CAUTION Over torquing fasteners could result in material failure Common Torque Specifications Cush Trailer Safety and Inspection Sticker Genera Fastener Torque Specs size tives win wax Alignment Support vehicle to unload suspension block compensators level loosen spring eye pivots and spring keeper bolts align vehicle re orque fasteners Torque Check torque after Break In period of approximately 1000 miles 1600 AI bolts and nuts should be checked to insure recommended torque values per insp ection schedule Itis important that these settings be maintained at imes to insure trouble free performance USH Giving the World a Better Ride Page 6 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Customer Welding Notes Itis the responsiblity 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 Tho suspension installer has the responsibility to determina the proper welding parameters for the materials being used For specifications of suspension component materials contact Cush Required vehicle support cross member locations may be shown Actual size and shape may vary per trailer design It is the resp
16. s industry standard replacement pivot bushing common replacement bolts rubber urethane trunion bushing heavy duty keeper sleeves replaceable spring seat wear pads low profile compensator structure Installer Responsibility INSTALLATION DISCLAIMER NOTES 4 his important tha the proper Cush suspension is chosen for the trailer application The folowing must bo considered when selecting a suspension required Suspension capacity loaded framo to ground measurement ge height axe travel axle Spacing and axis GAWR itis the responsibilty of the installer to determine tho correct location of the Suspension in order to provide proper vailor lad cetributon The gross axe weight rating GAWR of each axe must not exceed rated capacity of any ofthe components involved The suspension capacity ratings are or suspension components and axie beam 3 Required cross member locations maybe shown Actual size and shape may vary per design tis the responsibilty ot he suspension instaler to ensure structural adequacy of ihe trailer frame and related crose members Verily inat he actual trailor ross member locations correspond with onthe suspension drawing Alti the responsibilty of the suspension instaler to read tho instructions on the Sawing sheets thoroughly before proceeding wth a suspension instalation 5 adaitional lateral support is needed the suspension itis the responsibilty
17. tively absorb loads and maintain its shape In order to use standard the shelf replacement components bushings may require insert reducers to allow for spacing offsets and to accommodate smaller bolts that can be properly torqued to their effective 90 of proof load Tools required Shop wrenches bushing press bushing insertion tool per unit Disassembling Pivot Connection of Cantilever Spring On level ground securely chock the tires and apply trailer parking brakes Support the trailer in a safe manner at a working height Support the weight of the walking beam underneath the center Remove tires from the side that you will be removing the cantilever springs Loosen and remove pivot hardware from spring side to be replaced Inspect pivot connection area of compensator after removing spring It spring is to be placed in shop press you will need to remove each from the axle connection remove volts grind away axle seat connection welds between SH Giving the World a Better Ride CUSH SUPENSIONS SYSTEMS SERVICE MANUAL bottom seat and top seat leave axle welds connecting top seat to axle in place take apart axle seat and bottom to be able to remove spring leaves from bottom seat dowel pin Some models remove the flanged inserts from the inner diameter of the bushing tube Take spring to shop press and remove old bushing Clean debris from spring eye cavity iua Bushing lt
18. ust be of equal strength or approved by Cush Corporation in writing Warranty Note If after review of the Cush Corp Warranty it is determined that there is a warranty issue and Cush Corp has been notified then a Warranty Labor Allowance may ba 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 completo 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 0202 01 with an itemized list of charges and copies of all available receipts NOTE Get written approvaliwarranty estimate from Cush Corp before working on item that you would like to submit for a warranty claim Failure to do may eliminate your warranty claim CLSH Giving the World a Better Ride ET mH CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Suspension Service Items Axle Alignment Cush has several diferent alignment means available for diferent applications Listed hore are some general alignment guidelines and alignment procedures for the styles of Cush Alignment CAUTION DO NOT APPLY undercoating to the pivot alignment area until ater alignment and torque of the suspension pivot bolts Check that tho tire inflation pressure is correct on tires Alignment should be performed with th
19. walking beam On level ground securely chock the tres and apply trailer parking brakes Support the trailer in a safe manner at a working height Support the weight of the walking beam underneath the center Remove tres so that you can lower walking beam with axles from trailer Loosen and remove trunion cap nuts bolts and union cap Inspect the trunion and throw away the nuts and bolts so you will use new irunion fasteners Lower walking beam from trunion hanger Disassemble any other parts that interfere with lowering the assembly aut of the suspension hangers Inspect trunion area for any metal damage that could tear a new bushing Clean trunion area of any dirt or grime build up Ifis rubber no lubrication needs to be added If bushing is urethane add a thin coating of silicone grease around trunion tubo area Urethane bushings are used to allow freer articulation of the walking beam For rubber or urethane bushing a new bushing might come without a slit with a box knife cut a straight line on the bushing horizontal place the bushing on the union tube with the sit on horizontal centerline and centered in hanger Lit up walking beam and remount trunion cap by torquing bolts to specifications Spring Pivot Component Replacement The pivot of tha cantilever spring allows for more articulation and softer ride characteristics than steel spring walking beam This pivot bushing is made of rubber compound to effec
20. wear that might indicate an alignment problem Axle Alignment No pivot gear movement or inappropriate wear axles tracking properly Trailer Trailer not leaning trailer rame suspension attachment structurally sound no cracked missing welds at suspension frame attachment CushFLEX 90 day Inspection and at every brake lining change Thoroughly check all items checked at the 30 day inspection Also check All welded connections for signs of deterioration Al trame attachment joints and pivoting or clamping joints for problems retorque All spring eye bushings intact For any sagging or broken leaf springs CushFLEX Axle Alignment Inspection Check the Cush Algn connection for change of position at 30 day 90 day and every brake lining change Re align if necessary Re tack the alignment gear after adjustment to maintain position in heavy duty applications Axle Inspection general notes see axle manufacture s service manual for details Visually inspect the all axle components seals and hub caps for leaks and oil level every 6 000 miles f bath type Repair if necessary At 100 000 miles or 12 months visually inspect seal and hub cap for contaminants level or leaks Check the wheel bearing adjustment Repair amp retorque if necessary CLSH Giving the World a Better Ride Page 4 CUSH SUPENSIONS SYSTEMS SERVICE MANUAL Suspension Maintenance Items Tne Cush trailer suspension system is desi
21. with the addition of the optional lacking rack and more familar alignment means with the use of an eccentric adjustment c After axle alignment clamp the joint per Cush torque specifications c After torque of alignment fasteners the suspension installer to weld the outside washer to the compensator side with 1 welds to prevent tampering amp for off road applications An alternative to welding the alignment gears is to use optional add on rack ting locking plate that bolts into the alignment grounding nuts and secures the alignment gear WARNING After alignment clamp the pivot bolt per Cush torque specifications Torque the 12 rack lack bolts to 25 f Ibs loosen the rack lock bolts to realign pivot 2 5 Adjusting the Alignme a il realigning loosen the rack bons to allow eccentne cam movement I gears are tack welded grind off tacks The eccentric cam gear should always have the Indicator pointer te the top so that he eccentric wil be aligned withthe grounding nuts propery Set the alignment gaar indicator tab at 12 o clock the neutral postion Optional snug the rack lock bolts and pivot bots ot the Trac Align to be ight enough to hold the joint together but loose enough to permit use of ihe eccentric cam adjustment sure that the eccentric cam plate is clamped down lush against the hanger side and is not iding up the grounding m lsibars or that there any debris unde
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