SERVICE MANUAL FOR CHEVY C3500
Contents
1. sa alrioser os asyweDGE agin del al7iosse orfu mor 3 3 NM MM sa al71o8e1 02 aSY WEDGE AXLERH gt 27 1080422850 mrw s e 856x1 31x 095 PUZN K710343 Not shown 9 D710860 INSPECTION amp MAINTENANCE 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 is serviced Do the following during an inspection Fasteners Using a calibrated torque wrench check that all the fasteners are tightened to the proper torque Wear and Damage Inspect components of the suspension for wear and damage Look for bent or broken components Replace all worn or damaged components Operation Check that all components move freely through the complete turning arc a CAUTION Reyco Granning H 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 Y recommends the use of a maintenance pit or full vehicle lift during the inspection of components 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 regularly2. 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 on 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 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
3. 1 06 5 2 7o2385 0t WearPad 32 2l5081 REBOUND STRAP 8 25 e Zait Asy SpringBeam 34 _2 8219758 JN 3 4 16 Gr 5 ZP 35 2 81202378 N 1 2 13 Gr 5 ZP al 1 710882 02 Asy Wear Tower RH i 36 _ 2 710072 01 Shock Absorber o 1 702360 01 Asy Lower Air Spring Mount LH 37 ez Plate SerialNo 10 _1 702380 02 Asy Lower Air Spring Mount RH sel zeg Pop Rivet 1 8 dia x 525 long 30 Zeene HEIGHT CONTROL VALVE 12 16 702707 01 FHB7 16 14 125Gr8 27P 40 alsiso0020 HHB 1 4 20 x 3 4 Gr 5 ZN a 16 8120389 Fw 7 16 500x1 250x 083 ZP 1 alsi20380 siwis aa telses22200 LN 7716 14 UNC GR 8 42 4l8120375 Nut 1 4 20 Gr 5 ZP 45 ses HFW 3 406x 812x 085 ZN 43 _4 707069 01 MALE CONNECTOR 1 4T X 1 8MPT el el100270 P1 HHB 3 8 16 x 1 1 2 Gr 8 ZN vag 1 708580 01 Heat Shield Flexible LL el7o2505 ot LEN 2 8 16 Gr G ZN 1f710340 01 WEAR PAD BRACKET ASYLH 18 ales srcs3 8 24x2 00Gr 8 1 710240 02 weAR PAD BRACKETASYRH sel elas LFN 38 24 GrF ZINC 2fe274318 HHB12 20x5 GRS8 20 4 4356 srcs3 824x15GR8PH_ alimie rw s3x1082x 0e5z7P_ 21 elies FHB1 2 13x150 Gr8g 2 702385 01 Asy Ben Strap Mount Inner 22 af308 LEN 1 2 13 GR G ZN WE EH 50 6572 Spacer Rebound Strap 2837 23 2 5558 HHB1 2 13x450 Gr 5ZN 700953 07 HCW LINK NON ADJ 14 58 24 alsasso30 HHB 1 2 20 x 2 75 Gr 8 LN 1 4 28 GR 5 25 elses22302 LN 1 2 20 Gr
4. bolt torque Inspect for signs of chafing or wear X X Check for air line fitting torque Inspect for air leaks using soapy water solution Height Control Valve Inspect for signs of bending binding xxi Linkage or slippage Air Fittings and Air Inspect for air leaks using soapy water Lines solution Inspect for signs of chafing cracking x x or wear Shock Absorbers Check stud mount and lock nut torque Inspect shocks for signs of fluid leak broken eye ends loose fasteners or X X worn bushings Axle Connection Check U bolt nut torque xX X Wheels Check lug nut torque xX X Air Compressor Check air compressor compartment or enclosure for proper airflow and xX X venting Rear Alignment Inspect after first 1000 3000 miles K Air Fittings and Air Inspect for air leaks using soapy water Lines solution Inspect for signs of chafing cracking x lx or wear Continue to perform specified maintenance every 12 000 miles 2 A e S p See your vehicle s owner s manual for instructions regarding the maintenance of wheels and tires Wheel lug nuts must be retightened to proper torque specifications as per the vehicle or chassis manufacturer s Owner Guide 13 D710860 INSPECTION amp MAINTENANCE Maintenance Record Name of Owner oe of Owner Date of Purchase Name and Address of Dealer Model of Vehicle ehicle Identification Number Suspension Model Number Suspension Serial Number Inspection
5. 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 travel 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 If the 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 4 Repeat steps 1 thru 3 on other side 10 D710860 INSPECTION amp MAINTENANCE 5 Recheck ride height as stated in previous section Figure 2 Height Control Valve 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 8 e
6. of frame of air suspension mounting NOTE Do not brake or disconnect any electrical fuel or hydraulic lines FRAME DRILLING e This suspension requires no frame drilling Air Suspension Mounting 1 Upper Air Spring Pad Installation 1 1 Materials 1 upper air spring pad assembly left 702355 01 1 upper air spring pad assembly right 702355 02 8 flange head bolt 1 2 13 x 1 50 307 8 locking flange nut 1 2 13 308 1 2 Instructions Install upper air spring pad assemblies items 702355 01 8 702355 02 using the existing holes enlarged as print indicates and the fasteners listed above Torque to 90 ft lbs 2 Spring Beam Installation 2 1 Materials 2 spring beam assembly 5445 2 existing pivot bolt 2 existing nut 2 2 Instructions Install spring beam assemblies item 5455 to the hangers using the fasteners listed above Do NOT tighten at this time 18 D710860 INSTALLATION INSTRUCTIONS 3 Axle Wedge Assembly Installation 3 1 Materials 1 1 Spacer HCV Bracket LH 710861 01 1 1 Spacer HCV Bracket RH 710861 02 3 2 Instructions Install 1 Spacer assemblies items 710861 01 8 710861 02 between OEM axle seat and spring beam assembly 5455 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 4 Lower Air Spring Pad Assembly and Air
7. varying load conditions 3 D710860 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 comfort 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 is 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 in the air spring
8. Reyco SERVICE MANUAL FOR CHEVY C3500 Gr anning RD855C11 SUSPENSION SUSPENSIONS ISO 9001 2000 STANDARD TUTHILL 9098 West 800 South PO Box 600 Brookston Indiana USA 47923 Transport Technologies Tel 219 279 2801 Fax 219 279 2390 ww tuthill com S D710860 REV A 09 24 2010 TABLE OF CONTENTS Introduction vecina eed LA ee AMR lara leida 3 Company Pro le ea de ale 3 About RE E 6 General rer e A old ad 7 ACA A A A E 7 COMO a loe 8 E GE EE 9 Inspection Maintenance e ed den dae de 10 Height Control Valve Inspection amp Adjustment o ooococcnocccnocnnonnnoonnnonnnonn nono nonononann crac crnn canoso 10 ee e e 11 E ENT 12 Maintenance Rec A ica 14 Troubleshooting egener ot n a ria aio 15 Replacement Instructions ag WEEN a 17 Installation JOE sean esiis EE E aS E OESS aa 18 Installation Check Sheet A A 21 2 D710860 INTRODUCTION Company Profile Tuthill Transport Technologies is the Line of Business name arising from the acquisition and merger of two companies in the heavy duty suspension and off road axle industries Fluidrive Inc of Brookston IN which included the Granning brand and Reyco Industries Inc operating in Springfield MO Mt Vernon MO and Grimsby ON Canada Tuthill Transport Technologies is certified to the internationally recognized ISO 9001 2008 Standard This certification includes ReycoGranning operations ISO 9001 2008 is the highest international quality stan
9. Spring Assembly Installation 4 1 Materials 2 Lower Air Spring Plate 702360 01 2 Flange Head Bolt Y2 13x 3 0 705312 01 2 Air Spring Assemblies 5553 2 Nut 12 13 8120378 2 Jam Nut 4 16 8219758 2 Slotted Lock Washer Ye 8120384 4 2 Instructions Place lower air spring plates 702360 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 5553 to the spring beam spacer plate using the above fastener Position air spring assemblies so that the top studs line up with their mounting holes in the upper air spring pad assemblies 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 8 jam nut 8219758 Torque to 35 ft lbs 5 Axle Alignment 5 1 Materials None 5 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 t
10. allation 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 Electrical line wired correctly with 10 AWG min wire and protected to prevent cutting or chafing NOTE Improper wire size may cause compressor failure 21 D710860 INSTALLATION CHECK LIST 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 Height measured Check air system for air leaks using a soapy water solution 8 8 Ping Tanks if supplied Ping tanks installed as close as possible to the air springs All air line fittings to be installed with Perma
11. and Maintenance Date Mileage Service Performed Item 14 D710860 TROUBLE SHOOTING SYMPTOMS 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 excessively Vehicle ride is too harsh and or suspension contacts stops excessively ehicle ride is too soft POSSIBLE CAUSES REMEDIES 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 6 Check for air leak including the 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 orn 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 15 1 Put specified air pressure in tires 2 Balance or replace tires 3 Adjust ride height to specified setting 4 Align rear axle to specified thrust angle 5 Install correct tire and whee
12. 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 separately The dual system increases the sensitivity of side to side distributions of axle loading A 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 is a heated moisture ejector valve The valve is heated to eliminate ice build up This valve automatically releases accumulated water from the air tank every time the driving brake is used Each time the driver presses the brake pedal the ejection valve releases a bit more water insuring a well drained system There is 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 is 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 def
13. 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 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 alteratio
14. dard and is 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 developed by the International Organization of Standardization Tuthill Corporation is a privately held manufacturing company with facilities worldwide Tuthill s corporate offices are located in Burr Ridge Chicago Illinois Granning was founded in Detroit MI in 1949 and became part of Fluidrive Inc in 1985 Reyco was founded in Springfield MO in 1924 as Reynolds Mfg Co and assumed the Reyco Industries Inc name in 1956 Reyco Canada was established in 1963 with the opening of a facility located in Grimsby Ontario followed by the opening of another Reyco facility in Mt Vernon MO in 1973 Most recently in 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 in 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 ReycoGrann
15. e Lock Nut Lock Nut assure continued satisfactory vehicle pr O Co performance replacement fasteners used ee should be of the correct strength as well as the correct nominal diameter thread pitch Dots Dots length and finish Figure 6 Grade Markings on Lock Nuts Grade 1 or 2 11 D710860 INSPECTION amp MAINTENANCE Reyco Granning Recommended Torque Specifications Assembly Fastener Torque Ft Ibs Spring Beam Pivot Connection Shock Bolts Refer to Vehicle Owners Manual Wheels Refer to Vehicle Owners Manual 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 FIGURE A TIGHTENING U BOLT NUTS STEP TORQUE TO 50 ft lbs 100 lbs RDS55C11 FINAL TORQUE 109 ft lbs TORQUE TO 35 ft lbs TORQUE TO 90 ft lbs Se Te TORQUE TO As FIG A TORQUE TO 180 ft lbs FOR TORQUES 50 ft lbs 12 D710860 INSPECTION amp MAINTENANCE Maintenance Schedule GENERAL SERVICE TO BE PERFORMED MILEAGE IN MAINTENANCE THOUSANDS 12 24 36 48 60 72 84 96 Spring Beam Pivot Check bolt torque X Connection Inspect for contact between Spring X X Beam and Hanger Inspect for bushing wear X X Air Springs Inspect for proper clearance 1 minimum all around Check upper mount nut and lower mount
16. e Kit K710343 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 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 14 88 1 Linkage length is i Air lines installed to proper port on HCV see Height Control Valve Installation Drawing 710343 7 Air Kit Inst
17. e 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 is kneeled ReycoGranning ping 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 is plumbed directly to the air spring will show fluctuations depending on axle loading and vehicle operation 5 D710860 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 RD855C11 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 y
18. he 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 710858 01 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 6 Height Control Valve Installation 6 1 Materials 2 height control valve 5608 4 hex head bolt 20 x 75 8180020 4 Nut 20 Gr5 8120375 19 D710860 INSTALLATION INSTRUCTIONS e 4 SLW 8120380 2 height control linkage and studs 707069 01 e 4 Lock Nut 28 Grd 8454750 6 2 Instructions Install height control valve 5608 using fasteners 8180020 8120375 amp 8120380 See drawing 710343 for proper installation and correct orientation Torque to 8 ft lbs Install height control link 707069 01 using lock nuts 8454750 Torque to 10 ft lbs 20 D710860 INSTALLATION CHECK LIST Suspension Information RD855C1 1 Installer Installation Date Inspector Inspection Date Model Number Suspension Serial Number VIN Number Air Kit Options Referenced Drawings Installation Drawing D710859 Height Control Valv
19. ing 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 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 HI ambulances and class 3 through 8 truck applications This product line now exceeds 25 models that cover all major chassis utilized in the above applications Suspension Description A 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 is maintained whether lightly or heavily loaded This is the major difference between an air suspension and a conventional steel spring suspension The steel spring suspension is 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
20. l 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 5 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 required O Reattach or replace as required 1 Replace shock absorbers as needed 2 Adjust ride height to specified setting D710860 TROUBLE SHOOTING SYMPTOMS POSSIBLE CAUSES REMEDIES Suspension does not maintain 1 Air leak 1 Check connections with ride height 2 Internal leak in height controlisoapy water solution and repair alve or replace as needed 3 Height control valve linkage 2 Check height control valve loose and replace as required 4 Air spring chafed or worn 3 Check and tighten linkage as needed 4 Check air spring and replace as needed Air compressor runs excessively Air leak Inspect all air lines fittings and air springs with Internal air leak in height control valve a soapy water solution Repair retighten or Moisture ejector valve stuck ope
21. lated 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 air springs and shuts off exhaust from the air spring thus inflating the air springs The rear end of the vehicle is 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 the height control valve or kneeler 4 D710860 INTRODUCTION dump valve if installed These 200 cubic inch ping tanks effectively increase the volume of the air spring without having to utilize a larger air spring The spring rate of a system is 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 in 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 sid
22. ling characteristics Si al mi sac ar aa La En 5 A CA d Note The ride height is for the completed vehicle with body and components See table below for correct vehicle dimensions 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 is 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 wO IS OEI a A ey ne eee e an pen Figure 1 Suspension Identification 7 D710860 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 to activate this switch Exhaust Inflate Switch If the system is equipped with an optional kneeler exhaust valve s the control
23. n ireplace 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 interference Air compressor will not start Inline fuse burnt or circuit breaker tripped Replace or reset Air 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 16 D710860 REPLACEMENT INSTRUCTIONS amp WARRANTY R SERIES Replacement Instructions Reyco NOTE Due to the nature of service to be performed it is recommended Granning that a 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
24. n of the ReycoGranning AIRGLIDE drive axle suspension utilizing an automatic height control system is 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 e Switch the power to ON if OFF e Make sure the Exhaust Inflate switch is in the Inflate position if the suspension is so equipped If equipped check that the Low Pressure Warning Light and Buzzer is off The vehicle is ready for operation To exhaust the system if the suspension is equipped with an exhaust option e Make sure the vehicle is parked e Move the Exhaust Inflate switch to the Exhaust position e 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 8 D710860 PARTS LIST RD855C11 ITEM NO OTY PART NO DESCRIPTION rremMNO TY PART MO DESCRIPTION 28 elsow29288 HHN ege GR ASTM A194 2H t 1 70233001 Asy Hanger LH Asy Hanger RH LEN 5 8 18 Gr G PH Asy Upper Air Spring Mount LH 211 2f113 HHB 1 2 20 x 250 Gr 8 a 1 702355 02 Asy Upper Air Spring Mount RH 32 _2 4258_ Sleeve Rebound Strap
25. ns 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 TUTH LL 9098 West 800 South PO Box 600 3 Brookston Indiana USA 47923 l Transport Technologies Tel 219 279 2801 Fax 219 279 2390 www tuthill com 17 D710860 INSTALLATION INSTRUCTIONS Referenced Drawings RD855C11 Suspension Installation Drawing D710859 Height Control Valve Installation Drawing 710343 General Follow the step by step procedure below in the order given for proper installation Read the instructions thoroughly before starting installation CAUTION A 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 vehicle 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
26. our 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 warning 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 Granning gt s rear suspensions General Notes The following table lists the various models and their respective capacities Model Capacity Axle Capacity RD855C11 8 550 lbs 8 550 Ibs 6 D710860 GENERAL INFORMATION Overloading the suspension may result in adverse ride and hand
27. panel will have an Exhaust Inflate switch Moving the switch to Exhaust position exhausts all air from the air springs While the switch is in 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 in loading Caution Only operate the exhaust feature while the vehicle is parked Never exhaust the system while the vehicle is 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 in this condition The buzzer light will go off once 40 psi air pressure is reached The 5016 Control Panel Assembly with Power ON OFF only Included with the 9932 Air Control Kit INFLATE EXHAUST 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 is 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 Operatio
28. tex 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 22 D710860
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