ReaR axle & SuSpenSion - Central States Bus Sales, Inc.
Contents
1. 0 BLUE BIRD 202 e VISION SERVICE MANUAL SECTION 4 Parts Lists H COMFORT AIR 6 17730 246 APPENDIX COMFORT AIR KEY NO PART NO DESCRIPTION NO REQ KEY NO PART NO DESCRIPTION NO REQ 1 60784 000 Frame Hanger 2 57356 000 Lower Shock Bracket Assy 2 2 60632 001 QUIK ALIGN Kit Includes Key Nos 3 7 1 Includes Key Nos 30 33 34013 103 Pivot Bushing Service Kit Includes Key 30 Lower Shock Bracket 2 Nos 3 6 7 13 15 Services 1 Side Only 31 50764 002 1OUNC 5 50 Bolt 2 3 64107 000 1 8UNC 7 50 Bolt 2 32 22962 001 3 4 Hardened Washer 4 4 64097 000 QUIK ALIGN Concentric Collar 3 33 49842 000 3 4 10UNC Locknut 2 5 64096 000 QUIK ALIGN Eccentric Collar 1 50763 004 Cross Channel Fastener Kit Includes Key 6 22962 035 1 Hardened Washer 4 Nos 34 37 1 7 64108 000 1 8UNC Locknut 2 34 50764 003 3 4 3 50 Bolt 2 60925 002 Air Spring Assy Includes Key Nos 9 11 2 35 50764 005 3 4 1OUNC 3 00 Bolt 2 60929 002 Air Spring Assy Front Engine Includes 2 36 22962 001 3 4 Hardened Washer 8 Key Nos 9 11 37 49842 000 1OUNC Locknut 4 8 Air Spring 2 38 49177 006 Air Spring Fastener Kit Includes 1 9 57096 002 Air Spring Hanger 2 Key Nos 39 40 10 22962 014 Washer 2 39 22962 014 1 2 Hardened Washer 2 11 17700 010 1 2 13UNC Nylocknut 2 40 17700 010 1 2 13UNC Nylocknut 2 60779 000 MSM Assy Includes Key Nos 12 20 2 41 60998 001 Shock Absorber 2 12 Main Support Me2. 1 Install air spring in upper air spring hanger by inserting stud into hole and attach the 2 washer and locknut 2 Install air spring in spring seat by inserting stud into hole and attach the 2 washer and locknut 21 1 APPENDIX 217 0 BLUE BIRD 218 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR WARNING 1 APPENDIX 3 Tighten locknuts to A 20 30 foot pounds torque 4 Install brass fitting in air spring using Teflon thread seal 5 Connect air line to air spring 6 Remove jack stands and lower frame of vehicle 7 Air up system CROSS CHANNEL DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the 2 locknuts and washers that connect air springs to the cross channel and push air springs out of cross channel 5 Remove the 1 4 bolts washers and locknuts that connect the lower linkage mounting bracket to the cross channel See Parts Lists in Section 4 6 Remove 34 bolts washers and locknuts that connect the cross channel to the main support member assemblies 7 Remove cross channel ASSEMBLY 1 Install the cross channel to the lower shock absorber brackets and main support mem ber assemblies by att
3. 22 1 3 Verify air is removed from the system 4 Remove the 5 16 washer and locknut that attach the extension rod to the ride height control valve arm 5 Remove the air lines from the ride height control valve 6 Remove the brass fittings from the ride height control valve 7 Remove the 1 4 washers and locknuts that attach the ride height control valve to the frame mounting bracket 8 Remove fhe ride height control valve See Figure 7 13 Figure 7 13 Frame Height Control Valve Height Control Valve Link Assembly ASSEMBLY 1 Install the ride height control valve to the frame mounting bracket by attaching the 5 16 washers and locknuts Tighten to 3 80 90 inch pounds torque 2 Install brass fittings into height control valve using Teflon thread seal 3 Install air lines to ride height control valve 4 Install the height control valve link assembly to the ride height control valve arm by attaching the 5 16 washer and locknut Tighten to 80 90 inch pounds torque 5 Remove jack stands and lower frame of vehicle 6 Airup system 7 Verify proper ride height adjustment see ride height adjustment Preventive Maintenance Section of this publication 17730 246 25 1 0 APPENDIX BLUE BIRD 222 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR TRANSVERSE ROD DISASSEMBLY 1 Remove the 5 8 bolts washers and locknuts that connect the transverse torque rod to the frame bracket and axle
4. 2 Remove transverse torque rod ASSEMBLY NOTE 1 APPENDIX Hendrickson requires the use of Grade 8 bolts and Grade C locknuts be used for all rod attachments Install transverse torque rod by attaching the 5 8 bolts washers and locknuts to the frame bracket and axle See manufacturers for torque specifications 2 Verify lateral axle alignment and correct with drop in shims between the torque rod bar pin and the frame or axle bracket depending on the direction of alignment TRANSVERSE ROD BUSHING Remove transverse torque rods as detailed in the previous section DO NOT USE HEAT OR USE A CUTTING TO REMOVE THE BUSHINGS FROM THE TORQUE ROD THE USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE ROD HEAT CAN CHANGE THE MATERIAL PROPERTIES COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE You will need m vertical press with a capacity of at least 10 tons m Areceiving tool 5 long 2 inner diameter by 4 wall steel tubing 1 Supportthe torque rod end on the receiving tool with the end tube of torque rod centered on the tool Be sure the torque rod is squarely supported on the press bed 2 Push directly on the bushing straddle mount bar pin until top of the bushing is level to the top of torque rod end tube Press until the bushing clears the torque rod end tube 3 Clean and inspect the inner diameter of
5. AIR Plumbing Diagram 224 Delivery to Airspring Dump port Pressure protection X Continuous normally open Pr wit he 27 ess switch on dash Do not plug Exhaust port Air supply Plug this pot Y V 7 EN yl em E we DUREE me 7 Control ST Isl in cab Te us Sg MAS Sec BN Ya Airline S A E T SU LR D O T Compliant Is Ba Sis All others hoses s inch EN us sas Se Cu 5 y RU DS RSS 1 i EN MAN 28 17730 246 1 BLUE BIRD APPENDIX 0 p H REAR AXLE amp SUSPENSION APPENDIXES gt COMFORT AIR SECTION 9 Troubleshooting Guide COMFORT AIR TROUBLE SHOOTING GUIDE CONDITION POSSIBLE CAUSE CORRECTION Vehicle bouncing excessively Leaking shock absorber Replace shock absorber Damaged shock absorber Replace shock absorber Air spring s not inflated Check air supply to air spring repair as necessary ncorrect ride height Adjust ride height to proper setting See Ride Height Setting in the Preventative Maintenance Section of this publication Suspension has harsh or bumpy ride Broken main support member assembly Replace main support member assembly Damaged heig
6. ALIGN Tightening Torque Concentric Collar 525 575 ff lbs Pivot Bushing Secondary ON LS ME Main Support Member Puck ASSEMBLY 1 Install new frame hanger by attaching fasteners per vehicle manufacturer specifica tions 2 Install the new QUIK ALIGN collars new 1 dacromet pivot bolt washers and locknut that attach the main support member assembly to the frame hanger Verify that the nose of each QUIK ALIGN collar is installed into the pivot bushing sleeve and the flanged side is flat against the hanger face within the alignment guides NOTE The eccentric collar is located on the outside frame on the left side of chassis with the 1 APPENDIX concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger 14 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR 3 Snug the left pivot bolt to FN 100 foot pounds torque Tighten the right pivot bolt to A 525 575 foot pounds torque 4 Remove jack stands and lower frame of vehicle 5 Air up the system 6 Align the rear axle see alignment Preventive Maintenance Section of this publication MAIN SUPPORT MEMBER ASSEMBLY The Main Support Member Assembly should function satisfactorily during normal vehicle operation Replacement is only required when the Main Support Member Assembly has been damaged or worn Figure 7 2 Hanger E
7. Cap Tightening Torque 285 305 ft Ibs RIDE HEIGHT SETTING Proper ride height is essential for maximum ride quality and performance Proper adjust ment of the ride height control valve is described below If the valve or linkage assembly becomes damaged they will require replacement See the Component Replacement Section in this publication 1 Place vehicle on level floor 2 Freeand center all suspension joints by slowly moving the vehicle back and forth with out applying the brakes When coming to a complete stop make sure the parking brakes are released Chock front wheels of vehicle Loosen the clamp on the adjustable extension rod Remove the locknut and washer at height control valve leveling arm Verify that air system is at full operating pressure Exhaust the air in the air springs to relax the suspension Then refill the air springs to proper ride height oa Fr w 8 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR Dimension A The ride height can be measured at the centerline of the main support member assem bly as shown in Figure 5 2 The ride height is 47 8 1 4 at the A dimension shown Dimension B This option to measure the normal running length of the shock absorber will measure the ride height on the shock from center of eye to center of eye see dimension
8. Locknut 4 3 4 260 320 6 Air Spring to Cross Channel Locknut 2 1 2 20 30 7 Extension Rod Bracket to Cross Channel Locknut 2 1 4 40 50 in Ibs 8 Height Control Valve Arm to Extension Rod Stud Locknut 2 5 16 80 90 in lbs 9 Height Control Valve Studs to Frame Locknut 2 1 4 40 50 in Ibs 10 Adj Valve Arm Joint Stud to Bracket Locknut 2 5 16 80 90 in Ibs 11 Air Spring to Frame Bracket Locknut 2 1 2 20 30 12 Main Support Member Assembly Spring Clip Nut 2 7 16 30 34 NOTE 1 Follow torque specifications furnished by Truck Manufacturer s for OEM supplied fasteners The torque values listed above apply only if Hendrickson furnished fasteners are use 17730 246 3l 1 0 APPENDIX BLUE BIRD VISION SERVICE MANUAL 228 Information contained in this literature was accurate at the time of publication Product changes may have been made A a rm Truck Suspension Systems 630 910 2800 The Boler Company 800 S Frontage Road FAX 630 910 2899 Copyright O 2001 www hendrickson intl com All Rights Reserved 17730 246A 2M 12 01 Printed in United States of America Woodridge IL 60517 4904 1 BLUE BIRD APPENDIX 0
9. Torque U bolt fasteners Torque U bolts to 300 350 ft Ibs 34 39 Nm Air Suspension Inspect visually Check for wear damage loose or missing parts Torque upper shock mount Tighten to 50 70 ft Ibs 68 95 Nm Torque lower shock mount Tighten to 150 180 ft Ibs 203 244 Nm Check ride height Shock length eye to eye 22 68 25 576 6 Check U bolts 7 8 14 UNF 28 Tighten to 400 450 ft Ibs 542 610 Nm Check U bolts 3 4 16 UNF 28 Tighten to 260 320 ft lbs 353 434 Torque lower shock mount to spring Tighten to 260 320 ft Ibs 353 434 Nm Torque air spring anchor bolts Tighten to 20 30 ft Ibs 27 41 Torque quick align bolts Tighten to 525 575 ft Ibs 712 800 Nm Torque lever linkage locknut Tighten to 100 150 in lbs 11 17 Nm Torque Leveling valve mount bolt Tighten to 60 85 Ibs 7 10 Nm Rear Axle Viscosity Temperature Chart Meritor Lubricant Specification Description Cross Reference Minimum Outside Temperature Maximum Outside Temperature 0 76 Hypoid Gear Oil GL 5 S A E 85W 140 10 12 2 C 0 76 Hypoid Gear Oil GL 5 S A E 80W 140 15 F 26 1 C i 0 76 D Hypoid Gear Oil GL 5 S A E 80W 90 15 F 26 1 C Hypoid Gear Oil GL 5 S A E 75W 90 40 F 40 C 0 76 Hypoid Gear GL 5 S A E 75W 40 F 40 C 35 F 1 6 C 0 76 L Hypo
10. be replaced 11 Remove the main support assembly ASSEMBLY 1 Position main support member assembly on spring seat or on spacer plate if equipped with the main support member assembly center dowel pin piloting into hole in spring seat or spacer plate Galvanized steel liner must be positioned on the topside of the main support member assembly 2 Assemble the top pad U bolts axle bottom cap washers and locknuts DO NOT TIGHTEN U bolt locknuts at this time see Figure 7 4 WARNING DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY 3 Install NEW QUIK ALIGN collars NEW 1 dacromet pivot bolt washers and locknut Verify the nose of each QUIK ALION collar is installed into the pivot bushing sleeve and the flanged collar is flat against the hanger face within the adjustment guides DO NOT TIGHTEN at this time NOTE The eccentric collar is located on the outside frame on the left side of chassis with the 1 APPENDIX concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger 4 Position shock absorber and lower mounting bracket assembly on main support assembly b Position cross channel on main support assemblies Install 34 bolts washers and locknuts Tighten to 3 260 320 foo
11. body misting is not a leak and is considered acceptable m Shock is damaged internally jammed in the collapsed position It can also be deter mined by removing the shock shake and listen to the sound of metal parts rattling inside the shock body Figure 5 6 D im Welded Shock Mount x er Cover Leaking may occur from this area 1 Shock Body Lower Welded Shock Mount 17730 246 11 1 APPENDIX 0 BLUE BIRD 208 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR 6 Alignment ALIGNMENT Proper alignment is essential for maximum ride quality performance and tire service life The recommended alignment procedure is described below This procedure should be per formed if excessive or irregular tire wear is observed or any time the Main Support Member Assembly is removed for service The following procedure should be performed after all repairs are completed NOTE It is important to have the QUIK ALIGN locknut pre torqued to A 100 foot pounds on the left side of vehicle only All other suspension fasteners tightened to their specified torque values The total range of adjustment is 1 0 NOTE Use a new QUIK ALIGN kit Part No 60632 001 for any axle alignment or disassembly of 1 APPENDIX the QUIK ALIGN connection This ensures proper torque is applied to the connection 1 Place vehicle on level floor 2 Free and center all suspension joints by slowly moving
12. drive breaker bar rotate the left eccentric align ment collar to align axle Clockwise rotation moves axle forward counter clockwise rotation moves axle rearward A 90 rotation of the QUIK ALIGN collar will move axle fore and aft V2 from center DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY ENSURE THAT QUIK ALIGN FASTENERS TORQUE VALUE IS SUSTAINED AS RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION FAILURE TO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE m Measure from straight edge to forward face of axle arm to verify both sides of axle are equal and tighten the 1 QUIK ALIGN locknuts to 525 575 foot pounds torque NOTE The Eccentric collar is located on the outside frame on the left side of chassis with the concentric collar on the inside On the right side of chassis are 2 concentric collars located on the inside and outside of the frame hanger NOTE 17730 246 Axle adjustment is applied to LEFT side of vehicle only If adjustment to the right side of vehicle is necessary it will require replacement of the outside concentric collar with an eccentric collar Hendrickson Part No 64096 000 and repeat step 7 on the right side of vehicle 8 Following alignment of axle move
13. gt munus REAR AXLE amp SUSPENSION Overview The Blue Bird Vision is equipped with either a conventional leaf spring hydraulic shock absorber rear suspension or an optional Hendrickson Comfort Air rear air sus pension In both cases the rear axle assembly is an Arvin Meritor model RS 21 145 Whether the bus is equipped with air or hydraulic brakes wheel hubs and brake drums or rotors are mounted similarly The wheel hub with either an attached drum or rotor is mounted upon to the axle spindles Axle shafts pass through the center of the spindles and bolt to the outer flange of the wheel hub Thus the rear wheel bearings are lubricated by the axle oil This chapter describes the procedure for removal of the axle and suspension from the bus chassis Manufacturer s documentation is provided in the appendixes and on the TechReference CD for more involved servicing of the axle and suspenion components Towing the bus with the rear wheels on the road requires removal of the rear axle shafts in order to avoid potential damageto the automatic transmission See Jacking amp Towing in the Specs amp Maintenance chapter for the required procedure Appendixes In This Chapter Appendix 1 Comfort Air Rear Suspension Hendrickson Technical Procedure number 17730 246 covers maintenance disassembly adn troubleshooting for the Comfort Air rear suspension On The TechReference CD Rear Axle Arvin Meritor Maintenance M
14. providing a more comfortable and compliant ride It also provides neutral roll steer for better handling m Shock Absorbers Shock absorbers are tuned for optimum damping characteristics to provide maximum driving comfort m Air Springs Adjusts to changing load conditions to deliver superior ride quality m ULTRA ROD Lightweight and durable torque rod the ULTRA ROD is an integral component of the COMFORT AIR suspension that enhances handling during cornering and helps maintain lateral axle position m Height Control Valve Maintains precise ride height control through changing road surfaces load and driving conditions 2 17730 246 p H QUIK ALIGN SECTION 3 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR COMFORT AIR is available in suspension capacities up to 23 000 pounds and in ride heights of 8 5 and 10 5 The suspension weighs 487 pounds and includes the frame hanger brackets main support member assembly axle clamp group air springs shock absorbers cross channel upper and lower shock brackets ULTRA ROD transverse torque rod and frame bracket and height control system Figure 2 1 Frame Hanger Bracket Member IMPORTANT SAFETY NOTICE 17730 246 Proper maintenance service and repair is important to the reliable operation of the suspen Sion The procedures recommended by Hendrickson and described in this technical publi cation are methods of performing such maintenance ser
15. the press bed 18 17730 246 p H CAUTION WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR Figure 7 8 6 Locate the push out tool on inner sleeve and press in the new bushing Bushings must be centered within the spring eye When pressing in the new bushings over shoot desired final position by 3 16 and press again from opposite side to center the bush ing within the main support member assembly See Figure 7 8 7 Trim all protruding tape from the underside of the eye Wipe off excess lubricant Allow the lubricant four hours to dissipate before operating vehicle 8 Replace the two nylon pucks inside the secondary leaf eye 9 Slide secondary leaf around main support member eye and rotate into position 10 Place one liner between the secondary leaf and the main support member Place the second liner on top of the secondary leaf and tape the assembly together using two 1 x 12 long strips of splicing tape DO NOT WRAP EXCESSIVE TAPE AROUND THE ASSEMBLY AS THIS WOULD CREATE HIGH SPOTS IN THE CLAMP GROUP DO NOT WRAP TAPE AROUND THE ASSEMBLY MORE THAN TWICE FAILURE TO DO SO CAN CAUSE PREMATURE WEAR OR DAMAGE TO THE MAIN SUPPORT MEMBER 11 Install the 7 16 bolt and nut into the spring clip and tighten to A 30 34 foot pounds torque See Figure 7 4 12 Replace main support member assembly per instructions in this section SPRING SEAT BOTTOM CAP The spring seat and bottom c
16. the torque rod ends removing any nicks with an emery cloth or a rotary sander See Figure 7 14 4 Lubricate the inner diameter of the torque rod ends and the new rubber bushings with a vegetable base oil cooking oil see Figure 7 15 DO NOT use a petroleum or soap base lubricant it can cause and adverse reaction with the bushing such as deterio ration of the rubber 5 Press in the new bushings Support the torque rod end on the receiving tool with the end tube of torque rod centered on the receiving tool The straddle mount bar pin bush ings must have the mounting flats positioned at zero degrees to shank of the torque rod 6 Press directly on the straddle mount bar pin of bushing The rubber bushings of the bar pin must be centered within the torque rod end tubes 26 17730 246 REAR AXLE amp SUSPENSION APPENDIXES E H COMFORT AIR 7 When pressing in the new bushings overshoot the desired final position by approxi mately 3 16 see Figure 7 16 8 Press the bushing again from opposite side to center the bar pin within the torque rod end see Figure 7 17 9 Wipe off excess lubricant Allow the lubricant four hours to dissipate before operating vehicle 10 Replace torque rod assembly as detailed in the Component Replacement section Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 e 17730 246 27 1 0 APPENDIX BLUE BIRD vision SERVICE MANUAL COMFORT AIR H SECTION 8 COMFORT
17. the vehicle back and forth with out applying the brakes When coming to a complete stop make sure the parking brakes are released 3 Chock front wheels of vehicle 4 Verify proper ride height is set For proper ride height instructions see Ride Height Adjustment in this section of this publication Figure 6 1 2 Angle m 1 JI UJ 5 Using C clamps securely clamp a six foot piece of STRAIGHT bar stock or angle iron across the lower frame flange as shown in Figure 6 1 Select a location as far forward of the drive axle as possible where components will not interfere 6 Accurately square straight edge to frame using a carpenter s square 12 17730 246 p H WARNING REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR 7 Using a measuring tape measure from straight edge to forward face of drive axle arm at the centerline of the spring seat on both sides of vehicle as shown in Figure 6 1 and B If both sides measure within 1 8 of being equal alignment of drive axle is acceptable If A and B differ by more than 1 the following procedure must be fol lowed m Loosen the left pivot bolt locknut to snug 100 foot pounds See Figure 6 2 This will hold the eccentric flanged washer in place against the hanger face and within the adjustment guide but loose enough to permit the eccentric flanged washer to rotate freely m Using an alignment fool or 1 2 square
18. vehicle back and forth several times prior to remov ing straight edge from frame and recheck measurements to confirm adjustments 9 Repeat steps 7 and 8 until alignment is achieved Figure 6 2 Frame Hanger QUIK ALIGN Eccentric Collar 1 Washer 1 8UNC 7 5 Bolt 1 Locknut gt Tightening Torque X 525 575 ft Ibs QUIK ALIGN Y d Concentric Collar Pivot Bushing Puck 13 1 APPENDIX 0 BLUE BIRD 210 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR SECTION 7 Component Replacement FRAME HANGER The frame hanger should function satisfactorily during normal vehicle operation Replacement is required when the frame hanger has been damaged or worn DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the dacromet locknut and washers 1 pivot bolt and QUIK ALIGN collars that connect main support member assembly to frame hanger see Figure 7 1 5 Remove the fasteners that attach the frame hanger to the vehicle per vehicle manufac turer specifications 6 Remove frame hanger Figure 7 1 Frame Hanger 1 Washer QUIK ALIGN gt Eccentric Collar K 1 Washer TL 1 7 5 Bolt 1 Locknut QUIK
19. 4 1516 CR eg 6 Section 5 Preventive Maintenance Main Support Member Bushings 8 Bolt LoCKhUtS isis ns cedes eim edes ot cb bet 8 Ride Height Setting essen uns gen pu tige me Re Rente 8 Transverse ROUS su roseis eue n 10 cian nes te ob Mass dt 10 Section 6 Alignment rrr 12 Section 7 Component Replacement Fame Hange erac reed eth Pa e eee pup rise 14 Main Support Member Assembly 15 Main Support Member Assembly Pivot Bushing 17 Spring Seat Bottom 19 AID SPMING EP 21 Cross Channels ter pr 22 SHOCK ou ect Wane Ba ee oe aan 23 Upper Shock Absorber Frame 23 Lower Shock Absorber Bracket 24 Ride Height Control Valve 25 Transverse ettet ied edere dis 26 Transverse Rod Bushing 26 Section 8 COMFORT AIR Plumbing Diagram 28 Section 9 Trouble Shooting Guide 29 Section 10 Tightening Torque Specifications 30 2 HHENDRICKSON 1 0 APPENDIX BLUE BIRD 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR SECTION 1 Introdu
20. B in Figure 5 2 The specific running length of the shock absorber varies per specific OEM applications as shown in the matrix DIMENSION A DIMENSION B RIDE HEIGHT SHOCK ABSORBER LENGTH OEM AND MODEL FROM BOTTOM OF FRAME TO BOTTOM AT RIDE HEIGHT OF MAIN SUPPORT MEMBER WITH A TOLERANCE OF 1 4 BLUE BIRD RE QBRE 47 8 22 75 BLUE BIRD TCFE CSFE 47 8 22 75 BLUE BIRD TSFE CIFE 47 8 23 BLUE BIRD TCFE FLAT FLOOR 4 7 8 22 75 BLUE BIRD HDRE 47 8 22 75 BLUE BIRD CARE 47 8 22 75 Figure 5 2 7 Use 1 8 wooden dowel rod golf tee to set the neutral position for the height con valve by aligning hole in leveling arm with hole in control valve cover as shown in Figure 5 3 DO NOT use a metal rod or nail as this may cause damage to the height control valve Figure 5 3 To set neutral position 8 Reposition the extension rod in the rubber align hole with hole on joint height control valve cover 9 Attach washer and locknut and tighten to 3 80 90 inch pounds torque 10 Tighten clamp on the rubber joint with a screwdriver until securely fastened NOTE During cycle operation of the height control valve it is normal to experience a limited amount of exhaust noise 17730 246 9 1 APPENDIX 0 BLUE BIRD 206 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR ran H TRANSVERSE RODS The length of the transverse rod is determined by the vehicle manufacturer in order to cen ter the axles under the
21. CHING FASTENERS THE USE OF HEAT ON SUSPENSION COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF THE MAIN SUPPORT MEMBER DO NOT CONNECT ARC WELDING GROUND LINE TO THE MAIN SUPPORT MEMBER DO NOT STRIKE AN ARC WITH THE ELECTRODE ON THE MAIN SUPPORT MEMBER ASSEMBLY AND AXLE DO NOT USE HEAT NEAR THE MAIN SUPPORT MEMBER ASSEMBLY DO NOT NICK OR GOUGE THE MAIN SUPPORT MEMBER ASSEMBLY SUCH IMPROPER ACTIONS CAN CAUSE DAMAGE TO THE MAIN SUPPORT MEMBER ASSEMBLY COULD FAIL AND CAUSE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE 4 17730 246 fn H WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR PROCEDURES AND TOOLS A TECHNICIAN USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE VEHICLE S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED WILL ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED SHOCK ABSORBERS THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SUSPENSION ANYTIME THE AXLE ON A COMFORT AIR SUSPENSION IS SUSPENDED IT IS MANDATORY THAT THE SHOCK ABSORBERS REMAIN CONNECTED FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO SEPARATE FROM THE PISTON AND RESULT IN PREMATURE AIR SPRING FAILU
22. COMFORT AIR 17 Remove the U bolt locknuts and washers 18 Remove axle bottom cap AXLE BOTTOM CAP ASSEMBLY 1 Install axle bottom cap on axle in proper direction 2 Assemble U bolts washers and locknuts 3 Tighten U bolt locknuts evenly and tighten to the proper torque in the proper sequence see Figure 7 10 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to 3 285 305 foot pounds torque 4 Remove jack stands and lower the frame of vehicle 5 Air up the system AIR SPRING DISASSEMBLY Figure 7 11 Air Spring Frame Hanger 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from Air Spring VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE Suspension Lower Shock Bracket 34 TOUNC Locknuts 3 Verify air is removed from the system Cross Tightening Torque Channel 260 320 ft Ibs 4 Remove the 2 locknut and washer that connect air spring to the cross channel See Figure 7 11 5 Remove air line from air spring 6 Remove brass fittings from air spring 7 Remove the 12 locknut and washer that connect air spring to the upper air spring hanger 8 Remove air spring ASSEMBLY
23. LD RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO MACHINE OR MINOR PERSONAL INJURY NOTE An operating procedure practice condition etc which is essential to emphasize SERVICE HINT APPENDIX A helpful suggestion which will make the servicing being performed a little easier and or faster WARNINGS FASTENERS LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR SEVERE PERSONAL INJURY MAINTAIN CORRECT TORQUE VALUE AT ALL TIMES CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED LOAD CAPACITY ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION ADD ON AXLE ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED AND APPROVED CAPACITIES WHICH CAN RESULT IN COMPONENT DAMAGE AND LOSS OF VEHICLE CONTROL POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE MODIFYING COMPONENTS DO NOT MODIFY OR REWORK PARTS DO NOT SUBSTITUTE PARTS OF THE SUSPENSION USE OF MODIFIED OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY NOT MEET HENDRICKSON S SPECIFICATIONS AND CAN RESULT IN COMPONENT DAMAGE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS DO NOT MODIFY PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON TORCH WELDING DO NOT USE A CUTTING TORCH TO REMOVE ANY ATTA
24. RE PERSONAL PROTECTIVE EQUIPMENT ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTENANCE REPAIR OR SERVICE PARTS CLEANING SOLVENT CLEANERS CAN BE FLAMMABLE POISONOUS AND CAUSE BURNS TO HELP AVOID SERIOUS PERSONAL INJURY CAREFULLY FOLLOW THE MANUFACTURER S PRODUCT INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURES 1 WEAR PROPER EYE PROTECTION 2 WEAR CLOTHING THAT PROTECTS YOUR SKIN 3 WORK IN A WELL VENTILATED AREA 4 DO NOT USE GASOLINE OR SOLVENTS THAT CONTAIN GASOLINE GASOLINE CAN EXPLODE 5 HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY FOLLOW THE MANUFACTURER S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY TO HELP PREVENT PERSONAL ACCIDENT OR INJURY DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR POLISHED PARTS DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY QUIK ALIGN FASTENERS DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY ENSURE THAT QUIK ALIGN FASTENERS TORQUE VALUE IS SUSTAINED AS RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION FAILURE TO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE 1 APPENDIX
25. aching the 34 bolts washers and locknuts Tighten to A 260 320 foot pounds torque 2 Install air springs in cross channel by inserting studs into appropriate holes and attach washers and locknuts Tighten 2 locknuts to A 20 30 foot pounds torque 3 Install the lower linkage mounting bracket to the cross channel by attaching the 1 4 bolts washers and locknuts Tighten 4 locknuts to R 40 50 inch pounds torque 4 Remove jack stands and lower frame of vehicle 5 Airup system 22 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 H COMFORT AIR SHOCK ABSORBER DISASSEMBLY 1 Remove the Y2 locknut and washers that connect shock absorber to frame hanger See Figure 7 12 2 Remove the 34 bolt washers and locknut that connect shock absorber to lower shock absorber bracket 3 Remove shock absorber ASSEMBLY 1 Install shock absorber to frame bracket stud by attaching washers and locknut Washers must be installed on each side of shock absorber bushing 2 Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut 3 Tighten 2 locknut to A 50 70 foot pounds torque and 34 locknut to A 160 180 foot pounds torque Figure 7 12 z 5 Upper Shock 2 Locknut Tightening Torque 50 70 Fi Lbs KR Shock Absorber Lower Shock Lower Shock 34 Locknut Tightening Torque 160 180 Fi Lb
26. all new bolts 24 through the spring end assembly and the forward spring mounting bracket 11 lugs 22 Install new cotter pins 14 Ensure that any shim s removed during disassembly are replaced in the proper positions Ensure that the bolts 24 are oriented in the proper direction 194 23 Install shims 16 between the head of the bolts 24 and the lugs on the mounting bracket 11 24 Install new cotter pins 14 at rebound pins front and rear 25 Install flat washers 25 on bolts 24 26 Install hexnuts 26 27 Make standard check for dog tracking adjustment 28 When laser mark is within 1 4 inch of center adjusted with shims in step 23 above torque hexnuts 26 to 100 125 ft Ib 135 169 Nm 29 Using a crisscross pattern torque hexnuts 32 to 300 350 ft Ib 407 474 Nm in 10 ft Ib 13 Nm increments 30 Install flat washer 29 on bolt 28 31 Position the top end of the shock absorber 12 between the shock absorber brackets on the frame rails Ensure that the bolt 28 is properly oriented with the head toward the front of the bus 32 Install bolt 28 and washer 29 through the hanger brackets and the top end of the shock absorber 12 33 Install the flat washer 29 on bolt 28 34 Install hexnut 30 on bolt 28 Torque to 75 100 ft Ib 102 135 Nm 35 Position the lower end of the shock absorber 12 at the lower shock mount 3 Ensure the bolt 27 is properly o
27. ame section of this service manual Rear Spring Installation Installation of the rear spring suspension is accomplished in the reverse order of the removal instructions above and according to the torque values below TAM Always use new hardware when installing high torque suspen sion applications Torque hexnuts 26 at the rear hanger to 100 125 ft Ib 135 169 Nm Use new cotter pins 14 at the rebound pins 15 Bend each leg of the cotter pin at least 45 to secure it Torque hexnuts 30 to 75 100 ft Ib 102 135 Nm Torque hexnuts 32 to 300 350 ft Ib 407 474 Nm Torque hexnuts 40 to 106 112 ft Ib 144 151 Nm Install brake lines in accordance with instructions the Brakes Section of this service manual Install speed sensors in accordance with instructions in the Brakes Section of this manual Install wheels in accordance with instructions the Front Suspension Section of this service manual Rear Spring Axle Reassembly CAN Always use new hardware in high torque applications Never re use hardware in suspension applications 1 Position the axle saddle block 5 over the location pin on the axle housing 2 Position the spring assembly 7 in the saddle block 5 3 Position the U bolt seat 8 on the top of the spring 7 8 10 11 12 13 14 15 16 17 18 19 20 REAR AXLE amp SUSPENSION Position a new U
28. anual 5A includes thorough servicing infor mation on the disassembly inspection and servicing of the rear axles differential and reduction gears The RS 21 145 axle used on the Vision is a single speed axle without Driver Controlled Main Differential Lock DCDL Also See The Hydraulc Brakes chapter of this manual includes a detailed procedure for remov ing the rear disc rotor hub assembly 187 Single Reduction Rear Differential Carriers Maintenance Manual GO Single Reduction Rear Differential Carriers Meritor Publication Maintenance Manual 5A COMFORT AIR REAR SUSPENSION 1 0 APPENDIX BLUE BIRD VISION SERVICE MANUAL 188 0 BLUE BIRD Rear Axle amp Suspension INTERVAL 1000 Mites whichever occurs first 5 E 8s e e e 6 6 32 2 5 2 1 82 s ABS 4 Ss OPERATION El ssl ss gc NOTES Rear Axle Check lubricant Hypoid Gear Oil Capacity 35 pints 16 9 litres Change Lubricant Petroleum Based For viscosity recomendation see Axle Lubricant chart below Change Lubricant Synthetic Spring Suspension Inspect visually Check rebound pins Verify that cotter pins are installed Torque spring radius fasteners Tighten locknuts to 100 125 ft Ibs 11 14 Torque shock mounting bolts Tighten locknuts to 75 100 ft Ibs 9 11
29. ap are unlikely to require replacement In normal use they should function satisfactorily throughout the life of the vehicle Replacement is required when they have been damaged SPRING SEAT DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system and remove height control valve extension rod from valve by removing locknut and washer Remove the U bolt locknuts and washers See Figure 7 9 Remove U bolts axle bottom cap and pad Loosen the 34 bolts washers and locknuts that connect the cross channel to both main support assemblies 7 Lift cross channel and the main support member assembly with a jack 8 Remove spring seat oor 19 1 APPENDIX 0 BLUE BIRD 216 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR WARNING 1 APPENDIX H Figure 7 9 Main Support Member Assembly Spring Seat Lower Shock Bracket Axle Bottom Cap 7 8 Locknut 34 Locknut 7 Tightening Torque Tightening Torque 34 10UNC Locknuts 400 450 ft Ibs 285 305 ft Ibs Cross Tightening Torque Channel 260 320 ft Ibs SPRING SEAT ASSEMBLY 1 Install spring seat on axle in proper direction 2 Position main support assembly on spring seat or on spacer plate if so equ
30. bolt 9A the shorter U bolt at the forward groove in the U bolt seat 8 Position a new U bolt 9B the longer U bolt at the rearward groove of the U bolt seat 8 Position the lower U bolt bracket 4 over the ends of the U bolts 9A amp 9B Install the spherical washers 36 on the U bolt 9A 099 Flat washers 31 must be hardened Install the flat washers 31 on the U bolt 9A Loosely install the hexnuts 32 on U bolt 9A Install the spherical washers 36 on U bolt 9B at 2 places Install the stabilizer bar bracket 43 if so equipped on U bolt 9B Install the lower shock absorber bracket 3 on U bolt 9B Install flat washers 31 on U bolt 9B Loosely snugly enough to prevent movement install hexnuts 32 on U bolt 9B 0019719 prevent distortion of the U bolts tighten hexnuts 32 in crisscross pattern after initial contact snug Temporarily install the inner wheels and position the axle assembly in the hanger brackets to ensure the springs are located properly Then remove the wheels Position the rearward spring end 7 in the rearward spring bracket 10 Install the rebound pin 15 in the aft mounting bracket 10 Position the forward spring end 7 in the forward mounting bracket 11 Locate the spring radius leaf pin at the forward side of the bracket 11 Install the rebound pin 15 193 0 BLUE BIRD VISION SERVICE MANUAL 21 Inst
31. ccentric Collar Secondary Spring Clip Sleeve Main Support Member Spring Seat Lower Shock Bracket Axle Bottom Cap 7 8 Locknut OR Locknut Tightening Torque Tightening Torque 34 TOUNC Locknuts 400 450 ft 108 285 305 ff lbs Cross Tightening Torque Channel 260 320 ft Ibs DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system and remove height control valve extension rod from valve by removing locknuts and washers 4 Mark the position of QUIK ALION collar on the frame hanger SERVICE HINT Marking the position will create a starting point for the alignment procedure following assembly 5 Remove the 1 pivot bolt nut and QUIK ALIGN collars that connect the main support member assembly to the frame hanger see Figure 7 2 6 Remove the U bolts locknuts and washers 7 Remove the axle bottom cap and top pad 8 Remove the 34 bolts washers and locknuts that connect the cross channel to both main support assemblies 9 Lift cross channel off of the main support assemblies with jacks 17730 246 15 1 APPENDIX 0 BLUE BIRD 212 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR 10 Lift and rotate the shock absorber and lower mounting bracket away from the main support assembly to
32. ction This publication is to acquaint and assist maintenance personnel in preventive mainte nance and rebuild of the COMFORT AIRTM suspension system NOTE SECTION 2 Use only Genuine Hendrickson parts for servicing this suspension system Most Hendrickson parts can be identified by the Hendrickson trademark It is important to read and understand the entire Technical Procedure publication prior to performing any maintenance service repair or rebuild of the product The informa tion in this publication contains parts lists safety information product specifications features proper maintenance and rebuild instructions for the COMFORT AIR Suspension Hendrickson reserves the right to make changes and improvements to its products and publications at any time Contact Hendrickson Tech Services at 630 910 2800 for information on the latest version of this manual Product Description 1 APPENDIX The COMFORT AIR rear suspension system based on Hendrickson s proven HAS technology is designed for the needs of buses motor homes and ambulances The new system combines superior ride and handling with enhanced equipment protection m Frame Hanger Bracket Wide footprint distributes load over a larger area for reduced frame stress m QUIK ALIGN Fast and easy alignment without shims see Figure2 1 m Main Support Member Extended length generates lower spring rate for optimized roll stiffness
33. e pivot bushing into the spring eye If clip is damaged use the tape option as shown in Figure 7 7 Figure 7 6 Main Support Member Pivot Bushing Spring Eye Clip 5 Center the push out tool on inner sleeve and press out the old bushing These bush ings are not cartridge type bushings They do not have outer metals 6 Clean and inspect the 1 0 of the main support member eye ASSEMBLY 1 Insert the spring eye clip if equipped into the gap of the main support member eye see note above If spring eye clip is damaged or not present it is necessary to cut a strip of 3M Scotch 890T black fiber tape or heavy bodied duct tape 1 x 6 long 2 Feed the tape into the spring eye adhesive side facing gap in the eye Center the tape equally around each end 3 Pull the tape tight and wrap it around the outside of the eye Additional tape may be required depending on gap size Ensure that the gap is completely covered See Figure 7 7 Figure 7 7 REINFORCED TAPE LAID INSIDE THE SPRING EYE TO COVER THE SHARP SCARFED EDGE GAP 4 Lubricate inner diameter of steel spring bore and the new rubber bushing with a vegetable base oil cooking oil DO NOT use petroleum or soap base lubricant it can cause an adverse reaction with the bushing material such as deterioration 5 Support the main support member on the receiving tool with the end hub centered on the tool Be sure the main support member is squarely supported on
34. ech Services for proper Cross Channel 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 1 APPENDIX 0 BLUE BIRD 204 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR SECTION 5 Preventative Maintenance 1 APPENDIX MAIN SUPPORT MEMBER ASSEMBLY BUSHINGS Bushings should function satisfactorily during normal vehicle operation However prema ture bushing wear can occur and will require replacement The main support member assembly pivot bushing should be replaced if it exhibits excessive fore aft movement or the vehicle is experiencing excessive tire wear on the rear axle For instructions on bushing replacement see the Component Replacement section of this publication U BOLT LOCKNUTS Retighten to proper torque as shown in Figure 5 1 after the first 1 000 miles of service on new vehicle or vehicle with serviced axle attachment assembly and then at regular inter vals as experience dictates DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to AJ 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to A 285 305 foot pounds torque Figure 5 1 9 6 0 6 AE 2m L E d FN ry Sa D IERI 7 8 Locknu a Tightening Torque E 400 450 ft Ibs ine or 3 4 Locknut Axle Bottom
35. er to the upper frame bracket 5 Remove the bolt washers and locknut that connect the shock absorber to the lower bracket See Figure 7 12 6 Remove the shock absorber 7 Remove the 34 bolts washers and locknuts that connect the cross channel and lower shock absorber bracket to the main support member assembly on the affected side Loosen the 34 bolts washers and locknuts on the opposite side 8 Remove lower shock absorber bracket ASSEMBLY 1 Install the lower shock absorber bracket to the cross channel and main support mem ber assembly by attaching the 34 bolts washers and locknuts Tighten 34 locknuts to A 260 320 foot pounds torque 2 Install shock absorber to frame bracket stud by attaching washers and 2 locknut Washers must be installed on each side of shock absorber bushing 3 Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut 4 Tighten locknut to 50 70 foot pounds torque and 34 locknut to 160 180 foot pounds torque 5 Remove jack stands and lower frame of vehicle 6 Airup system 24 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR RIDE HEIGHT CONTROL VALVE DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension WARNING VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE
36. frame The transverse rod maintains lateral axle position during cor nering See Figure 5 4 The mounting bracket at the axle end of the torque rod is furnished and welded into position on the axle housing by the axle or vehicle manufacturer Figure 5 4 Bracket Supplied by Axle Manufacturer Torque rod end attaching fasteners are furnished by the vehicle manufacturer It is impor tant that the tightening torque of the nuts be checked during preventive maintenance serv ice Follow the vehicle manufacturer s specifications for tightening torque values All torque rods can be inspected for looseness or torn or shredded rubber With brakes applied slowly rock an empty vehicle with power while a mechanic visually checks the action at both ends Or with the vehicle shut down a lever check can be made with a long pry bar placed under each rod end and pressure applied Rod ends can be renewed by pressing out the worn end and installing a replacement bush ing A two piece rod is also available to cut and weld to the desired length see Hendrickson publication no 59310 001 NOTE 1 APPENDIX Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts be used for all rod attachments SHOCK ABSORBER INSPECTION Hendrickson uses a long life premium shock absorber on all COMFORT AIR suspensions When the shock absorber replacement is necessary Hendrickson recommends that the shock absorbers be replaced with identica
37. ht control valve Replace height control valve Excessive driveline vibration ncorrect ride height Adjust ride height to proper setting See Ride Height Setting in the Preventative Maintenance Section of this publication Broken main support member assembly Replace main support member assembly Air spring s not inflated Check air supply to air spring repair as necessary Vehicle leans Main support member assembly broken Replace main support member assembly Axle connection not torqued correctly Perform U bolt retorque procedure See Torque Specification Section of this publication Worn pivot bushing Replace pivot bushing Air spring s not inflated Check air supply to air spring repair as necessary Suspension is noisy Loose QUIK ALIGN attachment Replace QUIK ALIGN connection and check suspension alignment Check frame hanger for wear around QUIK ALIGN plates amp replace if necessary Loose U bolts Perform U bolt retorque procedure See Torque Specification Section of this publication Worn main support eye spacers Replace worn main support eye spacers pucks Worn main support clip spacers Replace worn main support clip spacers sleeves Irregular tire wear Worn pivot bushing Replace pivot bushing Loose QUIK ALIGN attachment Replace QUIK ALIGN connection and check suspension alignment Check f
38. id Gear Oil GL 5 S A E 75W 140 40 F 40 C No upper limit on these temperatures However axle sump temperature must never exceed 250 F 121 C REAR AXLE amp SUSPENSION Maintenance Maintenance of the rear axle and suspension consists of peri odic general inspection checking tightness of fasteners and axle lubrication fluid level check and or replacement Refer to the maintenance charts on the next page also included in the Specs amp Maintenance chapter for intervals and lubri cant specs Rear Suspension amp Axle Removal The following removal procedures were documented using a Blue Bird Vision bus with a Caterpillar 3126 engine and an Allison 2000 transmission Vehicles with other engine trans mission options may differ in detail VITAMIN Never work under a bus supported solely by hydraulic jacks Always use jack stands or blocks to secure the vehicle Ensure that the floor is firm enough to support the weight of the vehicle on the reduced footprint of the lifting holding device 1 Raise the vehicle observing all appropriate safety precautions for working under the bus 1 1 Park the bus on a level surface 1 2 Apply the parking brakes 1 3 Chockthe wheels opposite those being lifted 14 Using a jack or lift of sufficient strength lift the bus to take the wheels off the floor 1 5 Place jack stands or blocks of sufficient strength under the frame rails forward of the front spr
39. ilizer bar if so equipped by removing locknut 40 flat washers 42 and bolt 39 from each end of the axle 10 Todrop the axle remove hex nuts 32 flat washer 31 and spherical washer 36 from 4 places and lower the axle wheels assembly If working on only one end of the axle it is possible to do so by dropping only one side However care must be taken to avoid twisting the suspension on the other side Lower the end being worked on only enough to clear the location pins on the springs and axle This will make location of com ponents easier during reassembly 11 To drop the springs skip step 12 and remove and discard the cotter pin 14 from the rebound pin at the forward spring hanger 11 12 Remove the rebound pin 15 13 Remove and discard the cotter pin 14 from the rebound pin 15 at the rearward spring hanger 10 0 BLUE BIRD 192 0 BLUE BIRD VISION SERVICE MANUAL WID Carefully note the position of any shims in the next step During reassembly they must be replaced in the same positions 14 Remove hexnuts 26 flat washers 25 shims 16 and bolt 24 from 2 places at the rearmost spring hanger 11 15 Loosely install the inner wheels onto axle ends 16 Carefully lower the suspension axle wheels assembly and roll it out from under the vehicle CEN any frame members are to be removed or any suspension hangers they must be replaced in accordance with instructions in the Fr
40. ing hanger brackets 2 Remove rear wheels If only replacing shock absorbers skip to step 8 3 Disconnect the driveline at the differential by removing capscrews 17 and u joint straps 18 as illustrated at right 4 Suspend the driveline safely out of the way 0 BLUE BIRD DETAILA i c Q 5 2 Oo E Q E E REAR AXLE amp SUSPENSION 5 Disconnect the wheel speed sensors 6 If bus is equipped with hydraulic brakes disconnect the hydraulic lines at the frame rails 7 If bus is equipped with air brakes release the air pressure from the air tanks Then disconnect the air lines at the chassis frame rail 8 Remove Shock Absorber as follows KI 8 1 Lift the axle suspension assembly enough to take the weight off the suspension hangers 8 2 Remove hexnut 30 flat washers 29 and bolt 27 from the bottom end of the shock absorber 12 See Figure 2 8 3 Remove hexnut 30 flat washers 29 and bolt 28 from the top end of the shock absorber The shock absorber can now be removed When reinstalling shock abosrbers torque the bolts to 75 100 ft Ib 102 135 Nm Use the longer bolt at the bottom of the shock absorber Install the top bolt with its head toward the front of the vehicle Install the bot tom bolt with its head toward the rear See Rear Spring Suspsension Illustration on preceding page 9 Remove the stab
41. ipped with main support assembly center dowel pin piloting into hole in spring seat or spacer plate Delrin liner must be positioned on the topside of the main support member assembly 3 Assemble U bolts axle bottom cap washers and locknuts DO NOT TIGHTEN U bolt locknuts at this time 4 Tighten the 34 bolts washers and locknuts that connect the cross channel to the main support member assemblies to R 260 320 foot pounds torque Figure 7 10 5 Tighten the U bolt locknuts evenly and tighten to the proper torque in the proper sequence see Figure 7 10 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to R 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to A 285 305 foot pounds torque Remove jack stands and lower the frame of vehicle 7 Install height control valve link on control valve arm Tighten 5 16 lockwasher and nut to A 80 90 inch pounds torque Air up the system AXLE BOTTOM CAP DISASSEMBLY 1 Chock wheels of axle 2 Raise frame of vehicle to remove load from suspension VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 20 17730 246 p H WARNING 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7
42. l Hendrickson Genuine parts for servicing Failure to do so will affect the suspension performance and will void the warranty Inspection of the shock absorber can be performed by doing a heat test and a visual inspection For instructions on shock absorber replacement see the Component Replacement Section of this publication It is not necessary to replace shock absorbers in pairs if one shock absorber requires replacement 10 17730 246 REAR AXLE amp SUSPENSION APPENDIXES 7 COMFORT AIR HEAT TEST 1 Drive the vehicle at moderate speeds for fifteen minutes Figure 5 5 WARNING DO NOT GRAB THE SHOCK AS IT COULD POSSIBLY CAUSE PERSONAL INJURY DUE TO HOT SURFACE OF SHOCK BODY 2 Lightly touch the shock body carefully below the dust cover see Figure 5 5 3 Touch the frame to get an ambient reference A warm shock absorber is acceptable a cold shock absorber should be replaced SHOCK ABSORBER VISUAL INSPECTION PROCEDURE Inspect the shock absorbers fully extended Shock absorbers see Figure 5 6 will need to be replaced for any of the following m Damaged upper or lower mount m Damaged upper or lower bushing m Damaged dust cover and or shock body m Bentor dented shock m Leaking shock when streams of fluid travel down the side of the shock particularly from the upper seal The suspension is equipped with a premium seal on the shock however this seal will allow for misting to appear on the shock
43. mber 2 42 57322 002 Upper Shock Frame Bracket Assembly 2 13 58648 000 Pivot Bushing 2 Includes Key Nos 43 45 14 37674 051 Liner 4 43 Shock Frame Hanger 2 15 64817 000 Puck 4 44 50368 000 1 2 13UNC Serrated Shank Bolt 2 49175 026 Spring Clip Fastener Kit Includes Key 45 22962 031 1 2 Hardened Washer 2 Nos 17 18 Washer 19 46 49846 000 1 2 13UNC Locknut 2 16 Secondary Leaf 4 47 59013 000 Height Control Valve Kit Includes 1 17 64272 000 Spring Clip Sleeve 4 Key Nos 48 50 18 37042 002 7he 14UNC Bolt 2 48 Height Control Valve 1 22962 027 7 16 Washer Not Shown 49 22962 028 1 4 Hardened Washer 2 19 17700 007 7 16 14UNC Nut 2 50 49983 000 1 4 20UNC Locknut 2 20 Clip Bolt Spacer 2 Control Valve Lower Link Bracket Kit 1 21 56805 000 2 Includes Key Nos 51 54 57724 000 Top Pad 15 000 Ib capacity 2 57430 000 All Except Rear Engine U Bolt Kit 57430 003 Rear Engine Only 48718 7 8 Specify Length Includes Key 51 56789 000 Control Valve Link Bracket 1 Nos 22 23 24 25 58367 000 Control Valve Link Bracket Rear Engine 48718 104 3 4 15 000 Ib capacity Includes 52 56935 002 1 4 20UNC 1 00 Bolt 2 Key Nos 22 24 25 53 22962 028 1 4 Hardened Washer 4 22 47417 7 8 14UNF U Bolt Specify Length 4 54 49983 000 1 4 20UNC Locknut 2 49684 014 3 4 26UNF U Bolt 12 5 58994 Height Control Valve Link Assy Specify 1 15 000 Ib Capacity 4 Length Includes Key Nos 55 61 23 48574 000 Spherical Washer 8 55 Exte
44. nsion Rod 1 24 22962 002 7 8 Hardened Flat Washer 8 56 5 16 18UNC Jam Nut 2 22962 001 3 4 Hardened Flat Washer 57 gt 5 16 18UNC Locknut 2 15 000 Ib Capacity 8 58 5 16 Hardened Washer 2 25 50765 000 7 8 14UNF U Bolt Locknut 8 59 5 16 18UNC Stud 2 49685 000 3 4 16UNF U Bolt Locknut 60 Valve Arm Clamp 15 000 Ib Capacity 8 61 Adjustable Valve Arm Joint 1 26 48531 014 Spacer 1 5 As Required 2 62 62000 Transverse Rod Assy Specify Length 1 27 Spring Seat 2 63 49689 000 Torque Rod Shim As Req Meritor RS15 120 64 22186 000 Transverse Rod Frame Bracket 1 57022 010 4 5 Pinion Angle LH RH Meritor RS21 145 RS23 160 56501 006 4 5 Pinion Angle LH RH 56501 019 0 0 Pinion Angle LH RH SERVICE KITS QUICK REFERENCE 56501 020 4 5 Pinion Angle LH RH 56501 021 0 0 Pinion Angle LH RH 60632 001 QUIK ALIGN Kit Meritor RC23 160 34013 103 Pivot Bushing Service Kit 56501 020 Negative 4 5 Pinion Angle LH RH 49175 026 Spring Clip Fastener Kit 28 Axle Bottom Cap 2 50763 004 Cross Channel Fastener Kit Meritor RS15 120 49177 006 Air Spring Fastener Kit 57024 000 2 5 0 Pinion Angle LH RH 59013 000 Height Control Valve Kit Meritor RS21 145 RS23 160 Lower Control Valve Link Kit 50216 000 0 9 5 Pinion Angle LH RH 57430 000 All Except Rear Engine Meritor RC23 160 57430 003 Rear Engine Only 50216 000 Negative 0 9 5 Angle LH RH 48718 U Bolt Kit Specify Length 29 Cross Channel 1 48718 104 U Bolt Kit 15 000 Ib Capacity Contact T
45. rame hanger for wear around QUIK ALIGN plates amp replace if necessary 17730 246 29 1 APPENDIX 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR H SECTION 10 Torque Specifications 226 I sums 2 525 575 ff Ibs a 9 7 40 50 in lbs 20 30 ft Ibs Sy ae 450 70 ft Ibs 7 9 e is L H J NT lt 4 YA i 5 260 320 ft Ib LES SA 5 108 V9 3 160 180 ff lbs 7 8 Locknut OR Locknut Tightening Torque Tightening Torque 400 450 ff Ibs 285 305 ff Ibs 30 17730 246 BLUE BIRD APPENDIX REAR AXLE amp SUSPENSION APPENDIXES 7 H COMFORT AIR COMFORT AIR HENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS 1 U Bolt high locknut 19 000 to 23 000 Ib capacity 8 7 8 400 450 15 000 Ib capacity 8 3 4 285 305 Frame Fasteners Furnished amp Installed by Truck Manufacturer QUIK ALIGN Locknut 525 575 DO NOT ASSEMBLE QUIK ALIGN JOINT WITHOUT PROPER FASTENERS USE ONLY DACROMET PLUS XL PLATE WARNING FASTENERS TO MAINTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY 3 Shock Absorber Upper Shock Mount Locknut 2 1 2 50 70 4 Shock Absorber Lower Shock Mount Locknut 2 3 4 160 180 5 Cross Channel to Main Support Member
46. riented with the head toward the rear of the bus 36 Install a flat washer 29 on bolt 27 0 BLUE BIRD REAR AXLE amp SUSPENSION 37 Install bolt 27 and flat washer 29 through the lower end of the shock and install a flat washer 29 on the bolt 38 Position the lower end of the shock at the lower shock mounting bracket and install the bolt 27 and washer 29 assembly through the lower mounting bracket 39 Install a flat washer 29 and hexnut 30 on bolt 27 Torque to 75 100 ft Ib 102 135 Nm 195 40 Install brake lines in accordance with instructions in the Brakes Section of this service manual 41 Install speed sensors in accordance with instructions in the Brakes Section of this service manual 42 Install wheels in accordance with instructions in the Brakes Section of this service manual Air Rear Suspension For servicing the Hendrickson Comfort Air rear suspension see Appendix 1 of this chapter Hendrickson publication number 17730 246 0 BLUE BIRD lE E REAR AXLE amp SUSPENSION APPENDIXES H TECHNICAL PROCEDURE COMFORT AIR SUBJECT Service Instructions LIT NO 17730 246 DATE December 2001 REVISION A TABLE OF CONTENTS Section 1 2 Section 2 Product Description 2 Section 3 Important Safety 3 Section
47. s i UPPER SHOCK ABSORBER FRAME BRACKET DISASSEMBLY 1 Remove the gt locknut and washers that connect shock absorber to frame bracket 2 Remove the 34 bolt washers and locknut that connect shock absorber to lower shock absorber bracket 3 Remove shock absorber 4 Remove the fasteners that attach the upper frame bracket per vehicle manufacturer specifications 5 Remove frame bracket ASSEMBLY 1 Install the upper shock absorber frame bracket by attaching the fasteners per vehicle manufacturer specifications 17730 246 23 1 0 APPENDIX BLUE BIRD 220 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR 1 APPENDIX H Install shock absorber to upper frame bracket stud by attaching washers and lock nut Washers must be installed on each side of shock absorber bushing Install shock absorber to lower shock absorber bracket by attaching the 34 bolt wash ers and locknut Tighten Y locknut to 3 50 70 foot pounds torque and locknut to 160 180 foot pounds torque LOWER SHOCK ABSORBER BRACKET DISASSEMBLY 1 2 Chock wheels of axle Raise frame of vehicle to remove load from suspension VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE 3 Verify air is removed from the system 4 Remove the locknut and washers that connect the shock absorb
48. s MAIN SUPPORT MEMBER ASSEMBLY PIVOT BUSHING Figure 7 5 DISASSEMBLY Use a vertical shop press with a capacity of at least tons A 6 long piece of 4 I D by 25 wall steel tubing receiving tool is required A 6 long piece of 13 4 O D round bar stock with a 11 2 x 13 8 O D machined pilot push out tool is also required 1 Remove the 7 16 bolt clip bolt spacer and nut from the secondary leaf spring clip 2 the splicing tape that holds the liners to the center of the main support member assembly and rotate the secondary leaf to clear the spring clip from main support member 3 Slide the secondary leaf off of the main support member eye 4 Support the main support member on the receiving tool with the end hub centered on the tool Be sure the main support member is squarely supported on the press bed See Figure 7 5 17730 246 17 1 APPENDIX BLUE BIRD 0 214 0 BLUE BIRD vision SERVICE MANUAL COMFORT AIR 1 APPENDIX At the time of manufacture a spring eye clip was used to insert the pivot bushing into the spring eye of the the main support member See Figure 7 6 If spring eye clip is equipped on the main support member you have the option to carefully press out the bushing from the opposite side of the spring eye where the spring eye clip is NOT visible If the spring eye clip is not damaged it can be used again to facilitate the pressing in of th
49. t pounds torque 6 Snug 1 NEW QUIK ALIGN locknuts to 100 foot pounds torque Figure 7 3 7 Tighten the U bolt locknuts evenly and tighten to the proper torque in the proper sequence see Figure 7 3 rap top of U bolts and retighten to proper torque DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS m 19 000 to 23 000 pound capacity equipped with 7 8 locknuts tighten to 3 400 450 foot pounds torque m 15 000 pound capacity equipped with 3 4 locknuts to A 285 305 foot pounds torque 8 Remove jack stands and lower the frame of vehicle 9 Install upper extension rod stud onto the height control valve arm Tighten locknut to A 80 90 inch pounds torque 10 Air up the system 11 Align rear axle see alignment in the Preventative Maintenance Section of this publication 16 17730 246 REAR AXLE amp SUSPENSION APPENDIXES COMFORT AIR Figure 7 4 Frame Hanger A Concentric U Bolt Collar Eccentric Collar U 2 Bolt I Yt 9 I 1 Washer Top Pad 1 MM 7 6 Bolt E ix Tm il 3 15 Te d E NS Tightening Torque Puck MT 525 575 ft Ibs Bot Nu 7 ping ST ET 2 1 Pivot Bushing Q q i Seeya SI Cross Channel Clip Bolt Spacer Spacer if equipped Spring Seat Lower Shock 34 Locknut 160 180 1 Lbs Lower Shock Bracket 34 Locknut Tightening Torque 260 320 ft Ib
50. vice and repair The warnings and cautions should be read carefully to help prevent personal injury and to assure that proper methods are used Improper servicing may damage the vehicle cause personal injury render it unsafe in operation or void manufacturer s warranty Failure to follow the safety precautions in this manual can result in personal injury and or property damage Carefully read and understand all safety related information within this publication on all decals and that provided by the vehicle manufacturer before conducting any maintenance service or repair EXPLANATION OF SIGNAL WORDS Hazard Signal Words Danger Warning Caution appear in various locations throughout this publication Information accented by one of these signal words must be observed to help minimize the risk of personal injury to service personnel or possibility of improper service methods which may damage the vehicle or render it unsafe Additional Notes or Service Hints are utilized to emphasize areas of procedural importance and provide sug gestions for ease of repair The following definitions indicate the use of these signal words as they appear throughout the publication 1 APPENDIX 0 BLUE BIRD 0 BLUE BIRD VISION SERVICE MANUAL COMFORT AIR DANGER WARNING CAUTION INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COU
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