service manual for chevy c4500/c5500 rd11kc9
Contents
1. 37 D709754 INSTALLATION CHECK LIST Electrical line wired correctly with 10 AWG min wire and protected to prevent cutting or chafing NOTE Improper wire size may cause compressor failure Air lines and wiring installed without loops or bends Verify check valve orientation out of the compressor head arrow is to point away from compressor Air Compressor installed in a well ventilated enclosure and wired correctly positive to terminal labeled A1 amp negative to terminal labeled A2 NOTE Enclosure must protect the compressor from adverse environmental conditions see compressor decal Failure to do so may void warranty Air compressor higher than tank assy Check air compressor operation Verify ride height Remove excess linkage rod to prevent readjustment Height measured Check air system for air leaks using a soapy water solution 8 8 Ping Tanks Ping tanks installed as close as possible to the air springs All air line fittings to be installed with Permatex sealant or equivalent on threads Teflon tape is not to be used Air line SAE DOT brake line and protected in the installation with loom to prevent chafing or pinching on sharp edges 9 Additional Observations and Comments 38 D7097542. SERVICE MANUAL FOR CHEVY C4500 C5500 Gr anning RD11KC9 SUSPENSION SUSPENSIONS ISO 9001 2000 STANDARD A TUTH LL 9098 West 800 South Box 600 _ Brookston Indiana USA 47923 i Transport Technologies 219 279 2801 Fax 219 279 2390 5 www tuthill com D709754 REV B 08 04 09 TABLE OF CONTENTS CRT S 3 3 TMS Bd 6 Genera Doctus ioca vus ortos A TUA su 7 EIC E 7 9 9 rone Mena nuca aC Utm 12 Height Control Valve Inspection amp 12 Torgus Specio ONS Eris eto et at ete a 13 SCM CUS 15 Uds 16 TYOUDIG tuns ETEEN 17 19 4 System 9930 Height Control Valve System with kneeler valves 19 5 System 9932 Height Control Valve System w o kneeler valves 22 AB S
3. Perform a thorough visual inspection of the suspension to ensure proper assembly and to identify broken parts and loose fasteners each time the vehicle suspension 15 serviced Do the following during an inspection Q Fasteners Using a calibrated torque wrench check that all the fasteners are tightened to the proper torque Q Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all worn or damaged components Q Operation Check that all components move freely through the complete turning arc CAUTION Reyco Granning recommends replacing any damaged or out of specification components Reconditioning or field repairs of major rear suspension components is not allowed Note Refer to Section 1 for identification of components NOTE Reyco Granning recommends the use of a maintenance pit or full vehicle lift during the inspection of components A WARNING Never work under a vehicle supported by only a jack Jacks can slip or fall over and cause serious personal injury Always use safety stands Height Control Valve Inspection and Adjusting Suspension Ride Height The height control valve and linkage should be checked regularly for proper clearance operation and adjustment The ride height of the rear suspension is the distance from the bottom of the chassis frame rail to the center of the axle Properly adjusted ride height results in correct suspension tra
4. 34 8120303 FW 5 16 344x 68x 065 ZN 36 12 14 5157 TOGGLE SWITCH REDLIGHT 39 08706 HEIGHT CONTROL VALVE 20 70179901 TUBING 3 161Dx1 40Dx3 00 45 89429048 K706855 KIT LIFT CONTROL FITTINGS 707294 KIT COMPRESSOR ENCLOSURE K 706858 KIT HCV RD1350F AB Airline tubing should be 1 4 D O T plastic airline tubing me will result Check all connections for air leaks 3 Protective airline loom 1s recommended 30 The tubing ends must be cut straight and insert the full depth into the fittings otherwise leaks D709754 9905 AUXILIARY PING TANK KIT 8120371 N 1 2 20 Gr 5 ZP 0428 Connector 1 4T x 1 4MPT 0627 Connector 1 2T x 1 4MPT 8120384 SLW 1 2 523 x 873 x 135 3 0635 1 27 1 2 7 9 8455028 HHB 1 2 20x11 2 Gr 8 O Tank Air Ping 200 cu in 6 6248 Loom Braided Nonmetallic 0437 Elbow 45 deg 1 1 4 Installation on units Installation on units without dump valves with dump valves Notes l For best results the ping tank should be mounted as close to the air spring as possible 2 If the air system contains kneeler dump valves the above tank system must be inserted between the kneeler valve and the air spring 3 D709754 REPLACEMENT INSTRUCTIONS amp WARRANTY R SERIES Replacement Instructions Reyco NOTE Due to the nature of service to be performed it is recommended Gr
5. length and finish Figure 6 Grade Markings on Lock Nuts ve Grade 1 or 2 13 D709754 INSPECTION MAINTENANCE Reyco Granning Recommended Torque Specifications Spring Beam Pivot Connection OEM HEX FLANGE HEAD Upper Air Spring Pad Mount to Frame FHB 1 2 13 X 1 75 GR 8 ZN Lower Air Spring Assembly Mount to Beam HHB 7 13 x 3 00 Gr 8 ZN Stud Nut Air Spring N 1 2 13 GR 5 ZP JN 34 16 GR 52 FHB 318 16 X 1 25 ZING SFOS 3824 x 20 Gr HHB 1 4 20 X 75 GR 5 ZN Nut 8017 AXLE SEAT Shock Bolts Refer to Vehicle Owners Manual See Vehicle Owners Wheels Refer to Vehicle Owners Manual See Vehicle Owners Follow procedures and torques listed in Dodge Maintenance Manual Note Torque values listed above apply only if Reyco Granning supplied fasteners are used For information regarding component replacement or technical service call 1 800 753 0500 Air Port Nut Air Spring Backing Plate to Chassis Wear Pad to Backing Plate Rebound Strap Upper amp Lower Mount HCV bolts USE EXISTING CHEVY PIVOT BOLT amp NUT TORQUE TO CHEVY Y S SPEC TORQUE TO 40 ft los e TORQUE TO 35 ft lbs TORQUE TO 100 in Ibs TORQUE TO 35 ft lbs ORGUE TO 35 ft lbs di TORQUE TO 250 ft lbs FIGURE A amp m TIGHTENING U BOLT NUTS STEP TORQUE 50 ft lbs 100 Ibs 150 t Ibs 200 t Ibs 250 lbs amp E TORQUE TO 90 ft Ibs ECHECS
6. SHEET 3 WIRE BUTT CONNEZTOR TORQUE TO 6 FT LBS 4 PLACES Mounting bracket FEAR TO KNEELER CHASSIS VALVES MOUNT FIRST VALVE GROUND SECOND TO BOTTOM GF BRACKET CAUTION CHECK CLEARANCE BETWEEN VALVE AND AXLE IN KNEELED POSITION 19 12 DC ii BATTERY SEE HEIGHT CONTROL VALVE BB7D frame mounting passangsr sida existing in frame behind wear plate osser bly D709754 4 SYSTEM 9930 AIR SYSTEM WITH KNEELER VALVES TORQUE TO 84 FT LES 29 Starker Switch SIMPLIFIED starter CIRCUIT Battery m WX MED CA MEAE Dan AIR ASSEMBLY MOUNTING REQUIREMENTS 2 PLACES TORQUE FT LBS To Solenoid Goil Blue Wire Positive 12v From Supplied Switch Ta Chassia Ground FI Mute Y VIEW B hok aida of atopllght elrpult whan when brake pedal pressed CONNECTIONS Green Wire 85 Black Wire 874 Red Wire 30 Ralay and Harness White Wire amp amp P N 7035H3 04 sua nata 5 e AT OFF Switch Open OW Cloned Cloned CIRCUIT 1 CONTROL SIDE Pump vale Brake Ar Supply Cn 12 P
7. FINAL TORQUE 250 ft Ibs TORGUE SPEC 14 0709754 INSPECTION MAINTENANCE Maintenance Schedule GENERAL SERVICE TO BE PERFORMED MILEAGE IN MAINTENANCE THOUSANDS 12 24 36 48 60 7284196 Spring Beam Pivot Checkbolttorque X Connection Inspect for ean act between Spring Beam and Hanger Inspect for bushing wear Air Springs Inspect for proper clearance 1 minimum X all around Check upper mount nut and lower mount bolt torque Check for air line fitting torque X Inspect for air leaks using soapy water solution Height Control Valve Inspect for signs of bending binding or Linkage slippage Air Fittings and Inspect for air leaks using soapy water Lines solution a for signs of chafing cracking or Shock Absorbers Check stud mount and lock nut torque X Inspect shocks for signs of fluid leak broken eye ends loose fasteners or worn bushings Check U bolt nut torque enclosure for proper airflow and venting Rear Alignment Inspect after first 1000 3000 miles X X X p eie ETT Lines solution Inspect for signs of chafing cracking or wear Continue to perform specified maintenance every 12 000 miles 2 4 See your vehicle s owner s manual for instructions regarding the maintenance of wheels and tires Wheel lug nuts must be retightened to pr
8. spacer Spacer alignment pin seated correctly in axle mount seat 4 Clip Plate and U Bolt Installation Clip plate installed with correct orientation U bolts installed and torqued correctly at ride height Torque measured at Clearance between wear tower and wear block correct Clearance measured at 5 Air Spring Installation Air spring position correct and installed without any twist Adequate clearance around air spring to prevent chafing puncturing or overheating from exhaust Recommend 1 clearance around air spring to prevent chafing or puncturing Recommend min 3 clearance to any part of the exhaust system 6 Height Control Valve HCV Installation HCV positioned correctly with clearance around air springs Linkage installed correctly with clearance around air springs Linkage is the correct length 9 75 1 Linkage lengthis 2 Air lines installed to proper port on HCV see Height Control Valve Installation Drawing 0709008 7 Kit Installation Air tank assy installed correctly Automatic moisture emitter on bottom of tank Dump Valve kneeler valve installed with exhaust port down All air line fittings to be installed with Permatex sealant or equivalent on threads Teflon tape is not to be used Air line SAE DOT brake line and protected in the installation with loom to prevent chafing or pinching on sharp edges
9. use of components parts and or accessories not obtained from or approved by ReycoGranning Suspensions or which do not meet ReycoGranning Suspensions quality and performance specifications improper installation maintenance or repair misuse or abuse including but not limited to overloading or unauthorized alterations or modifications THE ABOVE WARRANTIES ARE SUBJECT TO THE WARRANTY LIMITATIONS AND REMEDIES SECTIONS OR REYCOGRANNING SUSPENSIONS INVOICE TERMS AND CONDITIONS This policy supersedes any previous warranty statements 03 2005 B B 9098 West 800 South PO Box 600 Brookston Indiana USA 47923 Transport Technologies 219 279 2801 Fax 219 279 2390 www tuthill cam 32 D709754 INSTALLATION INSTRUCTIONS Referenced Drawings RD11KC9 Suspension Installation Drawing 0709749 Refer to drawing 0708803 for all item numbers and views specified in this document Height Control Valve Installation Drawing D710057 General Follow the step by step procedure below in the order given for proper installation Read the instructions thoroughly before starting installation CAUTION minimum of 3 inches clearance must be maintained between tailpipe and air spring This may require alteration and or relocation of the tailpipe All modifications to the tailpipe must be in accordance with vehicle manufacturer s recommendations See Body Builders Layout Book VEHICLE PREPARATION 1 Secure vehi
10. ANKS amp WIRE HARNESS Gl Black Wire TORGUE B 4 PLACES Positive 12V From Ta Chassis Graund Supplied Switch Sea Motes Ta hat side of stoplight geut when when brake pedal 15 pressed B5 ATA 30 88 PRESSURE ELECTRICAL CONNECTIONS Recommended 0 FT LBS MEW 4 PLAGES COMPRESSOR ENCLOSURE pe 030 TANK ASSEMBLY REQUIREMENTS FOR ALTERNATIVE ENCLOSURE MOUNT To Spring 53 Aux switch CIRZUIT LOW PRESSURE WARNING SIDE o O INFLATE Ne pum Open oen UNION Sich Dieu a CIRCUIT 1 CONTROL SIGE EE EE Te Supply HC V Storter Bw JM OG ie 12 SIMPLIFIED IGNITION Starter CIRCUIT Hot Plat Tank Te AF Tonk Aggambly CIRCUIT 2 COMPRESSOR SIDE 4 41 Amp Baktay F cea Tabla E on Sheet 1 26 D709754 SYSTEM K706859 AIR SYSTEM WITH KNEELER VALVES PING TANKS amp WIRE HARNESS tem Description _ 00000 02 6 MALECON GAGHBxUSMPD s piss _ COMPRESSOR iSHPI2VDO 9 KV2L13 87S ELBOW 90 1 2T X 2MPT 20 8619 AIR PING 200 CU IN D706859 DWG AIR CONTROL KIT W HARNESS _ 706855 LIFT CONTROL FITTINGS 706855 KIT CONTROL FITTINGS K707294 KIT COMP
11. Control Valve Installation 9 1 Materials 2 height control valve 5608 4 hex head bolt 14 20 x 75 8180020 4 Nut 14 20 Gr5 8120375 4 SLW 8120380 2 height control linkage and studs 709953 03 4 Lock Nut 14 28 8454750 9 2 Instructions Install height control valve 5608 using fasteners 8180020 8120375 amp 8120380 See drawing 0710057 for proper installation and correct orientation 35 D709754 INSTALLATION INSTRUCTIONS Torque to 8 ft Ibs Install height control link 709953 01 using lock nuts 8454750 Torque to 10 ft lbs 36 D709754 INSTALLATION CHECK LIST omna Installer Installation Date Inspector Inspection Date Model Number Suspension Serial Number V I N Number Heferenced Drawings Installation Drawing D709749 Height Control Valve Kit D710057 Air Control Kit 0706859 RD11KC9 AB 9930 RD11KC9 4 9932 RD11KC9 5 0709308 RD11KC9 QR 1 Frame Drilling Hole position as required on installation drawing Note Holes must be drilled not torched 2 Wear Block Installation Backing plate installed Mounting bolts properly torqued Torque measured at Wear block mounting bolts not overtorqued wear block not warped Torque measured at 3 Beam installation Pivot bolts reinstalled correctly Pivot bolt torque correct at ride height Torque measured at Beam alignment pin seated correctly in
12. EM WITHOUT KNEELER VALVES M estie TANE ASSEMBLY 2 PLACES MOUNTING REGUIREMENTS TORQUE 90 Te Solanald Call Elua Wira Chossis Graund 4 See Hotes OM 12 Frar supplied Switch VIEW B To hot aldea of stoplight cIrzult when when brake padal is praaaed CONNECTIONS Green Wire 85 Recommended Black Wira Red Wire 341 White Wire une 24 2 PLACES Ralay and Harness 703685 01 4 PLACES TORQUE FT LBS i Sateh apan Switch Ced CIRCUIT 1 CONTROL SIDE Intermittent Stprier Switch Evitch SIMPLIFIED Starter CIRCUIT Maler Compressar vm d Tn Tank Assemb y CIRCUIT 2 COMPRESSOR SIDE Maln Batters wn 23 0709754 5 SYSTEM 9932 AIR SYSTEM WITHOUT KNEELER VALVES 4 6 709031 KIT HOV RD9TD AB 4 5 21 _ PLUG 14 PTSQUAREHEAD 8722 3 16 ID X 1 4 OD X 12 CV TUBE 93 8614 TANK AIR RESERVOIR 9 5392 VIBRATION ISOLATOR 34 8625 BRACKET AIR TANK MOUNT 10 8120214 i2 9429048 13 _ SWITCH TOGGLE 19 VOLT 35AMP 0705274 Drawing Air Kit Asy 14 910 CONTROLPANEL RD RTIRFD D9932 DWG AIRCNTRL DUALHCV prnueiserege jo To O 15 08 LFN 1 213 GR G ZINC 1 Airline tubing should be 1 4 D O T plastic airline tubing 2 The tubing ends must be cut s
13. RESSOR ENCLOSURE 0706858 KIT HCV RD1350F AB 1 Airline tubing should be 1 4 D O T plastic airline tubing 2 The tubing ends must be cut straight and insert the full depth into the fittings otherwise leaks will result Check all connections for air leaks 3 Protective airline loom 1s recommended 27 0709754 QR SYSTEM K709308 QUICK RECOVERY AIR SYSTEM HOD kK TO GROUND PLACE RESKER BATTERY HEAR BATTERY TERMINAL YEL LO WIRE RE EN WIRE PLACE BLUEIWIRE Tac RANGE WIRE a PROTECTED AREA HOOK TO GROUND BLAC EI IR GROUND H B LAC G RO UND 28 D709754 QR SYSTEM K709308 QUICK RECOVERY AIR SYSTEM 6 FT LBS 4 PLC TORQUE 13 FT LBS 5 PLO BOTH WIRES ARE BLACK HOOK 1 CHASSIS GROUND HOOK OTHER WIRE GREEN WIRE IN HAR NESS gt LOW PRESSURE SWITCH KNEELER VALVE Srl KNEELER VALVE LX KEYED POWER KNEELER SWITCH SYSTEM ON OFF SWITCH HEATER PRESSURE SWITCH T MIN BATTERY SO LENOID 4 D 40 AMP BREAKER 29 D709754 SYSTEM K709308 QUICK RECOVERY AIR SYSTEM ITEM PART DESCRIPTION ITEM DESCRIPTION 920141 PIPEPLUG I2NPT 27 0707294 WELDMENT COMPONENT ENCLOSURE 3 6 67 CONNECTOR 1 2T X 14MPT_ 31 12071 NI220GRSZN 8 100703 N1 420STOVER GR 8 ZN 33 12092 FW 1 4 281x 625x 065 Z2N 38 7 LENI2 IGR GZN
14. air springs and shuts off exhaust from the air spring thus inflating the air springs The rear end of the vehicle 18 automatically raised to the proper ride height Systems with dual height control valves require two kneeler valves one between each air spring and height control valve if the exhaust option is equipped To further improve the ride of an air suspension ReycoGranning offers a dual ping tank kit One ping tank is added to each side between the air spring and height control valve or kneeler dump valve if installed These 200 cubic inch ping tanks effectively increase the volume of the air spring without 4 D709754 INTRODUCTION having to utilize a larger air spring The spring rate of a system 16 directly proportional to the volume of the air spring The larger the air spring volume the lower the spring rate thus the better the ride However the amount of air flowing between the air spring and ping tank can limit the effective air volume of the system Therefore adding larger and larger ping tanks may not result significant changes in the suspension spring rate ReycoGranning ping tank kits have been designed to provide the ideal increase in volume and proper airflow A side effect in adding ping tanks is possible increase in air spring inflation times With a ping tank system installed the larger volume of air which improves the spring rate must be refilled each time the system 1s kneeled ReycoGranning pi
15. as to the aftermarket industry The R Series trade named AIRGLIDE are utilized by OEM customers in applications such as recreational vehicles shuttle bus trailer chassis builders Type I and III ambulances and class 3 through 8 truck applications This product line now exceeds 25 models that cover all major chassis utilized the above applications Suspension Description ReycoGranning AIRGLIDE drive axle air suspension system is a replacement rear suspensions system that consists of an air control system air springs trailing arm beams brackets and mounting hardware In general the air suspension works by maintaining a constant ride height by adjusting the amount air pressure in the air springs This allows the vehicle to remain level regardless of loading By varying the amount of air pressure in the springs a comfortable ride 15 maintained whether lightly or heavily loaded This 15 the major difference between an air suspension and a conventional steel spring suspension The steel spring suspension 1s usually designed for heavily loaded condition and thus yields a harsh ride in lightly loaded conditions In addition the steel spring suspension does not maintain a constant ride height under varying load conditions 3 D709754 INTRODUCTION By maintaining a constant ride height the horizontal center of gravity steering geometry and even the headlights remain level The benefits of an air ride are 1 Driver passenger comfo
16. cle by blocking the steering axle wheels and supporting the frame aft of drive axle 2 Raise drive axle to clear tires of ground and support axle 3 Remove tires 4 Remove the rear helper spring brackets and the leaf springs with rear shackles NOTE Retain all fasteners for air suspension installation 5 Remove the jounce bumpers from the frame rails 6 Clear all electric fuel and hydraulic lines in area of frame of air suspension mounting NOTE Do not brake or disconnect any electrical fuel or hydraulic lines FRAME DRILLING 1 Wear backing plates location Use backing plate assemblies items 709747 01 amp 709747 02 as templates Drill two 0 410 diameter holes per side for the backing plate See sheet 4 of D709749 for exact location Use existing holes where available and drill out if necessary AIR SUSPENSION MOUNTING 1 Backing Plate Assembly Installation 1 1 Materials 1 backing plate assembly left 709747 01 1 backing plate assembly right 709747 02 2 flange head bolt 1 2 13 1 50 307 2 locking flange nut 1 2 13 308 1 2 Instructions e Install backing plate assemblies items 709747 01 amp 709747 02 using the previously drilled holes and the fasteners 307 amp 308 e Torque items 702605 01 amp 708159 01 to 35 ft Ibs 2 Wear Pad 2 1 Materials 33 D709754 INSTALLATION INSTRUCTIONS e 1 wear pad left 709745 01 1 wear pad right 709745 02
17. d by the International Organization of Standardization Tuthill Corporation is a privately held manufacturing company with facilities worldwide Tuthill s corporate offices are located Burr Ridge Chicago Illinois Granning was founded in Detroit MI in 1949 and became part of Fluidrive Inc in 1985 was founded Springfield MO in 1924 as Reynolds Mfg Co and assumed the Industries Inc name in 1956 Reyco Canada was established 1963 with the opening of a facility located in Grimsby Ontario followed by the opening of another facility Mt Vernon MO in 1973 Most recently 2003 the Reyco Springfield facility merged with the Reyco Mt Vernon location to consolidate the Reyco line of products Tuthill Corporation purchased Fluidrive Inc in December 1998 and then purchased Reyco Industries Inc 1n February 1999 to offer Reyco Granning suspension solutions Reyco Granning air and steel spring suspensions are sold to truck trailer and specialty vehicle OEM s as well as truck equipment distributors All products are designed tested manufactured and marketed by members of the Reyco Granning team Congratulations on your purchase of a ReycoGranning AIRGLIDE drive axle air suspension system Founded in 1948 by one of the pioneers of air suspensions ReycoGranning Air Suspensions supplies drive and tag axle air suspension systems to a variety of original equipment manufactures as well
18. date is the responsibility of the first end user If the purchase date is not established to ReycoGranning Suspensions satisfaction the date of manufacture determined from the suspension system s serial number shall be used as the effective starting date When adjustment is sought under this warranty a claim should be made by contacting the distributor or manufacturer who installed the suspension who will coordinate the fix documentation parts shipment etc directly with ReycoGranning Suspensions NOTE ReycoGranning Suspensions must be notified in writing using a warranty claim form promptly upon claimed defect INSTALLER AND END USER RESPONSIBILITIES The Distributor Installer is responsible for installing the product according to ReycoGranning Suspensions approved procedures the installer is also responsible either directly or through its agent dealer for providing a copy of ReycoGranning Suspensions warranty and owner s manual to the end user and for advising the end user of proper use service and maintenance required for the product The end user is responsible for operating inspecting and maintaining the suspension according to the instructions in the ReycoGranning Suspensions owner s manual and any applicable vehicle owner s manual and for properly instructing all operators and maintenance personnel NOTE Warranty may be denied for improper installation LIMITATIONS AND EXCLUSIONS No warranty applies in the event of
19. ict Air Teri Tonk CIRCUIT COMPRESSOR SIDE 20 D709754 4 SYSTEM 9930 AIR SYSTEM WITH KNEELER VALVES 6 6115 _ MALECON GAeHBxUSMP 29 por FHBy213X112GR8ZINO 8 biss COMPRESSOR i HPI2VDC 70260001 90 1 4T X IAMPT 0428 CONNECTOR X 1 4MPT 32 8899 12 Bro 5 16 ID X 1 4 OD X 12 CV TUBE 19 8942904 Noneis GRSZP D7os274 Drawig Air Kit Asy 20 4951 _ BWITCH TOGGLE 12 0 DWG AIRONTLKIT 21 Bur jwmcHTOGGLEGEDLIGHD 1 Airline tubing should be 1 4 D O T plastic airline tubing 2 The tubing ends must be cut straight and insert the full depth into the fittings otherwise leaks will result Check all connections for air leaks 3 Protective airline loom is recommended 21 0709754 5 SYSTEM 9932 AIR SYSTEM WITHOUT KNEELER VALVES 16 AWG 210 29 14 E gt 2 e 12 AWG D 3 r Vehlcig Light L1 fra hot elde of slap light circuit Power when broke Net Battery SEE HEIGHT CONTROL 15 pressed SWITCH PANEL LAYOUT TORQUE 13 FT LBS NONLIGHTED SWITCH COMPRESSOR FRONT VIEW MOUNTING CONFIGURATION Keyed Power Not Battery 275 pu 1 PRESSURE SWITCH 4 38 AND RELAY a 2n COMPRESSOR MOUNTING REQUIREMENTS REAR VIEW 22 0709754 5 SYSTEM 9932 AIR SYST
20. ng tank kits have been designed to minimize this effect while improving the ride Finally optional warning light sensors or air pressure gauges may be plumbed to either the air reservoir tank or to the air springs These warning devices will indicate possible problems with the air suspension system prior to operation Gauges that are plumbed to the reservoir tank will read between 95 and 125 psi as described above Any air gauge that 1s plumbed directly to the air spring will show fluctuations depending on axle loading and vehicle operation 5 D709754 INTRODUCTION About This Manual This publication is intended to acquaint and assist maintenance personnel in the maintenance service repair and rebuild of the Reyco Granning RD11KC9 Rear Suspension It is important to read and understand the entire Technical Procedure publication prior to performing any maintenance service repair or rebuild of this product Reyco Granning Air Suspensions reserves the right to modify the suspension and or procedures and to change specifications at any time without notice and without incurring obligation Contact customer service at 800 753 1060 for information on the latest version of this manual You must follow your company safety procedures when you service or repair the suspension Be sure you read and understand all the procedures and instructions before you begin work on the suspension Reyco Granning uses the following types of notes to give war
21. ning of possible safety problems and to give information that will prevent damage to equipment A WARNING A warning indicates procedures that must be followed exactly Serious personal injury can occur if the procedure is not followed A CAUTION A caution indicates procedures that must be followed exactly Damage to equipment or suspension components and personal injury can occur if the procedure is not followed NOTE A note indicates an operation procedure or instruction that is important for correct service Some procedures require the use of special tools for safe and correct service Failure to use these special tools when required can cause personal injury or damage to suspension components The latest revision of this publication is available online at http www Reyco Granning com Reyco Granning Air Suspensions has developed this service manual to aid in the maintenance of Reyco s rear suspensions General Notes The following table lists the various models and their respective capacities Axle Capacity RD11KC9 11 000 Ibs 11 000 Ibs 6 D709754 GENERAL INFORMATION Overloading the suspension may result in adverse ride and handling characteristics R 48 81 9 55 RIDE HEIGHT 3 00 REBOL ND Note The ride height 1s for the completed vehicle with body and components See table below for correct vehicle dimensions See following pages for the above views Gra
22. nninge Jounce Rebound Travel Travel Chassis Suspension Height Model Chevy Sierra 4500 5500 Cab Chassis 86 3o Ride height is measured from the axle center flat and level to the bottom of the vehicle frame at the rear of vehicle behind the axle as shown Identification The suspension model and serial number are stamped on an aluminum tag that 1s riveted to the driver side upper Hanger Weldment See Figure 2 The serial number is used by Reyco Granning for control purposes and should be referred to when servicing the suspension See Figure 1 Re CO Manufactured by Granhing fA SUSPENSIONS I SERIAL GAWRILBS O IRDTTKC 111 000 MAY BE COVERED BY THE FOLLOWING FATENTS OTHER PENDING U S 4 506 210 6 158 750 6 176 501 Pi CANADA 1 194 044 2 Figure 1 Suspension Identification 7 D709754 CONTROLS Descriptions of the typical controls are found below Note some original equipment manufactures OEM will use controls integrated into the instrument panel While the appearance may differ the operation and description are consistent with below Power ON OFF Switch This master switch turns the power off and on to the compressor and other electrical components of the drive axle suspension To activate the compressor and other electrical components move the switch to ON The vehicle ignition switch may need to be turned on
23. o 8 flat countersunk hex screw 3 8 24 x 1 50 702635 01 8 locking flange nut 3 8 24 304 2 2 Instructions e Install wear pads items 709745 01 amp 709745 02 to the backing plate assemblies using the available holes and the fasteners listed above Torque 100 in lbs 3 Upper Air Spring Pad Installation 3 1 Materials e 1 upper air spring pad assembly left 705057 01 e 1 upper air spring pad assembly right 705057 02 e 8 flange head bolt 1 2 13 x 1 50 307 o 8 locking flange nut 1 2 13 308 3 2 Instructions e Install upper air spring pad assemblies items 705057 01 amp 705057 02 using the previously drilled holes and the fasteners listed above Torque to 90 ft lbs 4 Spring Beam Installation 4 1 Materials e 2 spring beam assembly 705090 01 e 2 existing pivot bolt e 2 existing nut 4 2 Instructions e Install spring beam assemblies item 705090 01 to the hangers using the fasteners listed above Do NOT tighten at this time 5 Axle Wedge Assembly Installation 5 1 Materials e 1 1 Spacer Bracket LH 709978 01 e 1 1 Spacer Bracket RH 709978 02 2 3 8 705065 01 5 2 Instructions e Install 3 8 spacer item 705065 01 on top the axle seats The pin in the spacer should sir in the axle seat e Install 1 Spacer assemblies items 708537 01 amp 708537 02 in between 3 8 spacer and spring beam a
24. off once 40 psi air pressure 1s reached The 5016 Control Panel Assembly with Power ON OFF only Included with the 9932 Air Control Kit The 5008 Control Panel Assembly with Power ON OFF and Kneeler Dump Valve Switches Also shown is the 1069 Air Pressure Gauge 0 160 psi and the 5401 Alarm Light Buzzer The 5008 Control Panel Assembly 16 included with the 9930 Air Control Kit The 1069 Gauge and 5401 Light Buzzer are included in the optional 5703 Warning Kit Air pressure sensing may also be performed by and OEM installed interface control panel To exhaust the system if the suspension is equipped with an exhaust option Make sure the vehicle 1s parked Move the Exhaust Inflate switch to the Exhaust position When exhausted switch the power to OFF if desired Although the air suspension master power switch can be left ON ReycoGranning recommends turning the system off while the vehicle is parked for an extended period if the suspension system is not switched through the vehicle ignition switch This will avoid running down the battery If equipped check that the Low Pressure Warning Light and Buzzer is off The vehicle is ready for operation 9 0709754 PARTS LIST 7 Sr 24 Y AN D709754 PARTS LIST Tin B L Ll dl K710057 Not shown 10 D709754 PARTS LIST 11 0709754 INSPECTION MAINTENANCE
25. oper torque specifications as per the vehicle or chassis manufacturer s Owner Guide 15 D709754 INSPECTION MAINTENANCE Maintenance Record TROUBLE SHOOTING SYMPTOMS POSSIBLE CAUSES REMEDIES Tires wear out quickly or have uneven tire tread wear Note Wear pattern will indicate possible cause s Consult tire manufacturer for guidance ehicle rolls side to side Vehicle ride 1s too harsh and or suspension contacts stops excessively ehicle ride 1s too soft 1 Tires have incorrect pressure 2 Tires out of balance 3 Incorrect ride height 4 Incorrect rear axle alignment 5 Improper mismatched tires and wheels 1 Shock absorbers worn 2 Shock eye bushings worn 3 Axle U bolts are loose 4 Loose or worn Spring Beam Pivot connection s 5 Loose or worn Spring Beam Pivot bushing s height control valve 1 Shock absorbers worn 2 Incorrect ride height 3 Vehicle overloaded 4 Air spring supply lines leaking or obstructed 5 Vehicle system air pressure below specification 6 Jounce bumper in air spring worn or broken 7 Air Suspension not turned on 8 Defective Height Control alve s 9 Height Control Linkage disconnected or damaged 1 Shock absorbers worn 2 Incorrect ride height 17 6 Check for air leak including Replace as required 1 Put specified air pressure in tires 2 Balance or replace tires 3 Adjust ride height to specified
26. or valve stuck open replace as required Note Plastic air lines must Check valve installed incorrectly be cut square See Air Control System Parts List Dump valve s or kneeler s leaking General Notes for additional notes Height Control Valve stuck in the exhaust Insert exhaust tube into a cup of water and position examine for bubbles This will show evidence of both inlet and exhaust valve leaks Replace components Check and replace if necessary Arrow should point away from the air compressor head Correct if necessary Check and replace if necessary Locate obstruction and remove or relocate compressor will not start Inline fuse burnt or circuit breaker tripped compressor motor burnt out Inspect and replace as required Disconnected or broken wire Inspect and correct or replace if necessary Ignition switch and or suspension power switch Turn on ignition switch and or suspension not on switch 18 0709754 4 SYSTEM 9930 AIR SYSTEM WITH KNEELER VALVES Shoo Light DIrcult hat of Keyed Power stop light circuit Not Battery when brake pedal SEE TABLE pressed CT LIGHT TURN WHEN EXHAUST FUSITION DOMPRESSOR MOUNTING GCOMFIGURATION ga non 005 2 7 E NONLICHTED SWITCH B FRONT VIEW COMPRESSOR MOUNTING REQUIREMENTS HEAT SHRINE TUBE Keyed Powar Nat Battery TO PRESSURE SMTH RELA Y B
27. rt 2 Protection of cargo chassis and body components 3 Reduced stress fatigue to chassis frame rails 4 Greater stability and control A unique feature to the ReycoGranning AIRGLIDE drive axle air suspension system is the wear towers and wear blocks These time proven components prevent unwanted side to side lateral motion without the use of costly and complex track rods Air Control System A primary subsystem of a ReycoGranning AIRGLIDE drive axle air suspension system is the air control system Depending on the actual system used the air control system will provide the ability to automatically control the amount of air pressure in the air springs thus automatically control the suspension ride height The major components of an automatic air control system consist of an air compressor reservoir tank height control valve and air spring The operation of the system is simple The compressor supplies air to the tank which maintains the air pressure between 95 125 psi Air from the tank 1s supplied to the height control valve The height control valve supplies air to or depletes air from the air spring via a mechanical linkage based on axle loading The pressure changes the air spring but the height remains the same thereby giving the optimum ride regardless of load A system with a single height control valve supplies both air springs simultaneously while a dual height control valve system supplies each air spring separatel
28. setting 4 Align rear axle to specified thrust angle 5 Install correct tire and wheel combination 1 Replace shock absorbers as needed 2 Check and replace as needed 3 Tighten see previous torque chart or replace as required 4 Tighten see previous torque chart or replace as required 6 Check height control valve and replace as required 1 Replace shock absorbers as needed 2 Adjust ride height to specified setting 3 Check wheel loads and correct as needed 4 Check air line connections and remove obstructions 5 Check air pressure and correct as needed 6 Check and replace air spring as required 7 Turn on air suspension 8 Replace height control valve as 1 Replace shock absorbers as needed 2 Adjust ride height to specified setting D709754 TROUBLE SHOOTING SYMPTOMS POSSIBLE CAUSES REMEDIES Suspension does not maintain 1 Air leak 1 Check connections with soapy ride height 2 Internal leak height control water solution and repair or alve replace as needed 3 Height control valve linkage 19 Check height control valve and loose replace as required 4 Air spring chafed or worn 3 Check and tighten linkage as needed 4 Check air spring and replace as needed compressor runs excessively Air leak Inspect all air lines fittings and air springs with Internal air leak in height control valve soapy water solution Repair retighten or Moisture eject
29. ssemblies See drawing sheet 3 for proper installation Be sure axle wedge assemblies are positioned correctly they must be centered on spring seats and parallel to them with the F forward and on top for proper axle alignment 6 Wear Tower Assembly Installation 6 1 Materials 1 Wear tower assembly left 709748 01 1 Wear tower assembly right 709748 02 4 U bolt 705059 01 8 flat washer 3 4 812x1 475x 150 103003 8 Lock high nut 3 4 16 6868 2 lower clip plates Re use OEM lower clip plates 6 2 Instructions e Install wear tower assemblies item 709748 01 amp 7099748 02 onto the spring beam assemblies using the fasteners listed above e Re install lower clip plates OEM Do NOT tighten at this time 34 D709754 INSTALLATION INSTRUCTIONS 7 Lower Air Spring Pad Assembly and Air Spring Assembly Installation 7 1 Materials 2 Lower Air Spring Plate 705062 01 2 Flange Head Bolt 12 13 3 0 705312 01 2 Air Spring Assemblies 8896 2 Nut 12 13 8120378 2 Jam Nut 34 16 8219758 2 Slotted Lock Washer 1 2 8120384 7 2 Instructions 8 Axle Ali Place lower air spring plates 705062 01 on the beam spring and align the holes Place flange head bolts 705312 01 up through the hole in lower air spring pad assemblies Attach air spring assemblies 8896 to the spring beam spacer plate using the above fastener Position air spring assemblies so tha
30. t the top studs line up with their mounting holes in the upper air spring pad assemblies See D709749 sheet 3 for proper installation Torque flange head bolts 705312 01 to 35 ft lbs Install air spring assemblies to the upper air spring pad assemblies using the available holes and nut 8120378 slotted lock washer 8120384 amp jam nut 8219758 See D708146 sheet 2 for proper installation Torque to 35 ft lbs gnment 8 1 Materials None 8 2 Instructions Make sure the spring beam assemblies are positioned properly The spring beam assemblies must be attached properly to the axle wedge assemblies and the axle wedge assemblies must be attached properly to the axle seats with no space between any of them Make sure they are parallel to each other Position and support the axle at ride height Torque spring beam pivot bolts to OEM spec Make sure there is no space between the wear tower assemblies and the spring beam assemblies and they are parallel to each other Verify the clip plate wear towers are equally spaced on both sides from the wear blocks and located approximately 090 to 120 away front the wear blocks If not adjust axle location and or clip plate assembly locations to achieve this Torque u bolt nuts item 6868 to 250 ft lbs A criss cross pattern must be used to torque these AXLE ALIGNMENT NOTE An improperly aligned axle will result in premature wear of vehicle s tires and suspension wear pads 9 Height
31. that qualified mechanic do the work SUSPENSIONS Limited Warranty ReycoGranning warrants its R Series suspensions to be free from defects in material and workmanship under normal use and service in the U S and Canada Main Structural Components 24 months or 50 000 miles whichever occurs first Defined as hangers beams clip plates and axle saddles Other Air Suspension Components 12 months or 24 000 miles whichever occurs first valves fasteners bushings and other components not stated specifically when provided by ReycoGranning and other fabricated metal components ReycoGranning provides no warranties on components such as axles air springs controls air compressors brakes shock absorbers and hub and drum assemblies except to the extent of any warranty provided to ReycoGranning Suspensions by the manufacturer of such components Labor 6 months or 12 000 miles whichever comes first Labor will be allowed ReycoGranning Suspensions estimated time to make repairs at a maximum rate of 50 00 per hour As used herein the term normal use and service means that the suspension will be installed operated inspected and maintained in accordance with the applicable ReycoGranning Suspensions owner s manual and any applicable vehicle owner s manual or instructions Adjustments The starting date for the above warranty period is the date of purchase of the suspension by the first end user Proof of such
32. to activate this switch Exhaust Inflate Switch If the system 1s equipped with an optional kneeler exhaust valve s the control panel will have an Exhaust Inflate switch Moving the K N INFLATE E L E R EXHAUST Operation of the ReycoGranning AIRGLIDE drive axle suspension utilizing an automatic height control system 1s reached through various control panels Depending upon options included with the suspension system the control panel should be operated as follows Before operating the vehicle Switch the power to ON if OFF Make sure the Exhaust Inflate switch 1s in the Inflate position 1 the suspension 1s so equipped switch to Exhaust position exhausts all air from the air springs While the switch 1s the Exhaust position the air springs will remain deflated Exhausting air from the air springs may be required to assist in maintenance and lower the rear of the vehicle to assist 1n loading Caution Only operate the exhaust feature while the vehicle 1 parked Never exhaust the system while the vehicle 1s in motion To inflate the air springs place the switch in the Inflate position Gauges Lights Buzzers As an option the Air Pressure Warning Light Buzzer kit may be installed The gage will indicate air tank pressure If air pressure falls below 20 psi a warning light and buzzer will activate Do not operate the vehicle 1n this condition The buzzer light will go
33. traight and insert the full depth into the fittings otherwise leaks will result Check all connections for air leaks 3 Protective airline loom is recommended 24 D709754 SYSTEM K706859 AIR SYSTEM WITH KNEELER VALVES PING TANKS amp WIRE HARNESS Hamers n 101 101 x hot side of stop light circuit Powar when brakm padol amp Mat Buttery SEE HEIGHT COHTROL 21030304 iai Induded an LR Wiring Hanes 706923 0 4719 12wDC kavad 26 Power Net Battery Tabla B SWITCH LAYOUT TORGUE TO 13 FT LBS ALIX SWITCH TO AIR KNEELER VALVES RESER vOIF 4 PLACES 030 M ELUE WIRE 4 38 TO 07121 01 WIRING HARNESS POWER SWITCH a FRONT MEW COMPRESSOR COMPRESSOR SOR END MOUNTING CONFIGURATION MOUNTING REQUIREMENTS COR HEAT SHRINK TUBE TO PING TANK Keyed Power Not Battery PRESSURE SW TCH RELAY BLUE WIRE TO 707121 01 MPE BUTI TORQUE TO FT LBS CONNECTOR QUE B FT WIRING HARNESS BLACK WIRE TO GROUND Lb 2 50 REAR VIEW TO KNEELER MOUNT FIRST VALVE TOP PING VALVES DUMP AND SECOND TO BOTTOM OF BRACKET MOUNTING HOLES CAUTION CHECK CLEARANCE BETWEEN ONLY TWO REQUIRED WALVE AND AXLE IN KNEELED POSITION 23 D709754 SYSTEM K706859 AIR SYSTEM WITH KNEELER VALVES PING T
34. vel and alignment The ride height should not be adjusted to adjust chassis rake angle To check ride height 1 Park the vehicle on a level surface 2 Ifthe suspension is equipped with kneelers lower the suspension 3 Re inflate the air suspension Allow the Suspension to settle 4 Set the parking brake and block the drive wheels to prevent vehicle movement 5 make sure nothing is interfering with the travel of the height control valve arms 6 Measure the distance from bottom of chassis to center of axle on each side The ride height should be 8 65 inches To adjust ride height 1 Loosen nut on side of HCV arm 2 Slide short arm up or down as needed 3 Torque nut to 30 to 45 in lbs 12 0709754 INSPECTION MAINTENANCE 4 Repeat steps 1 thru 3 on other side 5 Recheck ride height as stated previous section Figure 2 Height Control Val TORQUE SPECIFICATIONS Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of Figure 5 Grade Markings on Bolts fasteners for a given application To Grade Lock Nut Lock Nut assure continued satisfactory vehicle KENNEN performance replacement fasteners used Identification should be of the correct strength as well as the correct nominal diameter thread pitch 3 Dots 6 Dots
35. y The dual system increases the sensitivity of side to side distributions of axle loading schematic of each system can be found in the Air Control System Parts List section See Air Control System Control Panels and Operation sections Located on the bottom of the air tank assembly 1s a heated moisture ejector valve The valve is heated to eliminate 1 build up This valve automatically releases accumulated water from the air tank every time the driving brake 16 used Each time the driver presses the brake pedal the ejection valve releases a bit more water insuring a well drained system There 15 a small round button port in the center of the underbelly of this valve Press this button with your finger to manually drain accumulated water from the tank when the vehicle is turned off Optional kneeler or exhaust valve s may be plumbed between the air springs and the height control valve s When power 1s applied to these valves they shut off air supply from the height control valve to the air springs and exhaust air from the air springs As long as power is supplied to the kneeler valve usually through the exhaust position of the inflate exhaust switch the air springs will remain deflated With the air springs deflated the rear end of the vehicle will remain lowered or kneeled with the chassis resting on positive jounce stops Removing power to the kneeler valve allows air to flow from the height control valve to the
36. ystem 706859 Height Control Valve System w ping tanks and kneeler 1 25 QR System K709308 Quick Recovery System 28 2905 Auxiliar Pins Taak 10900528 3l Replacement Instructions and nennen 32 Wah ey muero cu oL E 33 Installatiom Deck ohe do Odo ua e EM CI EE 37 2 0709754 INTRODUCTION Company Profile Tuthill Transport Technologies is the Line of Business name arising from the acquisition and merger of two companies the heavy duty suspension and off road axle industries Fluidrive amp Inc of Brookston IN which included Granning brand and Reyco Industries Inc operating Springfield MO Mt Vernon MO and Grimsby ON Canada Tuthill Transport Technologies is certified to the internationally recognized ISO 9001 2000 Standard This certification includes ReycoGranning operations ISO 9001 2000 1s the highest international quality standard and 1 recognized worldwide by all major countries and corporations To obtain certification a company must undergo a series of rigorous audits to remain certified and ensure consistent quality standards are being maintained This quality standard was develope
Download Pdf Manuals
Related Search