97117-242 Subject: HINO RK BUS ARB MODIFICATION Date: August 2020 Revision: N

BUS SUSPENSION TECHNICAL BULLETIN

No: 97117-242 Subject: HINO RK BUS ARB MODIFICATION Date: August 2020 Revision: N

REAR ARB KIT FRONT ARB KIT

Introduction As a result of significant vehicle testing, Hino and Hendrickson Asia Pacific Pty Ltd have completed development of a front and rear Anti-Roll Bar (ARB) kit, specifically designed for the Hino RK1J Series Bus configured with air suspension. The kit consists of: a. Front PARASTEER™ Suspension ARB Kit – 97113-010 b. Rear COMFORT AIR™ Suspension ARB Kit – 97113-007 c. Extended Torque socket for rear axle U-bolts. – 98825-004 The ARB kits contain all the necessary hardware, engineering layout drawings and parts list.

Purpose

The purpose of this bulletin is to provide a detailed installation procedure for the front and rear Anti-Roll Bar (ARB) kits.

Reference Technical Bulletins: A. Front Suspension – 17730-234 – PARASTEER™ Service Instructions B. Rear Suspension – 17730-246 – COMFORT AIR™ Service Instructions

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Important Safety Notice The procedures recommended by Hendrickson and described in this technical publication are methods of performing the described installation and to ensure reliable operation of the suspension ARB.

The warnings and cautions should be read carefully to help prevent personal injury and to assure that proper methods are used. Non-adherence to safety measures may cause personal injury, render the vehicle unsafe in operation, cause damage to the vehicle, 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 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 minimise the risk of personal injury to service personnel, or possibility of improper service methods which may damage the vehicle or render it unsafe.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Additional ‘Notes’ or ‘Service Hints’ are utilised to emphasise areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these signal words as they appear throughout the publication.

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, CAN RESULT IN SERIOUS INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY, OR PROPERTY DAMAGE.

NOTE: An operating procedure, practice condition, etc. which is essential to emphasise.

SERVICE HINT: A helpful suggestion, which will make the servicing being performed a little easier and/or faster.

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Safety Precautions

FASTENERS LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE, OR SEVERE PERSONAL INJURY. MAINTAIN CORRECT TORQUE VALUES AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED.

AIR SPRINGS AIR SPRING ASSEMBLIES MUST BE DEFLATED PRIOR TO LOOSENING ANY CLAMP GROUP HARDWARE. UNRESTRICTED AIR SPRING ASSEMBLIES CAN VIOLENTLY SHIFT. DO NOT INFLATE AIR SPRING ASSEMBLIES WHEN THEY ARE UNRESTRICTED. AIR SPRING ASSEMBLIES MUST BE RESTRICTED BY SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE BEYOND PRESSURES RECOMMENDED BY AIR SPRING MANUFACTURER, CONTACT HENDRICKSON TECHNICAL SERVICES FOR DETAILS. IMPROPER USE OR OVER INFLATION MAY CAUSE AIR SPRING ASSEMBLIES TO BURST, CAUSING PROPERTY DAMAGE AND/OR SEVERE PERSONAL INJURY.

WHEN SERVICING THE VEHICLE OR ATTACHING AN AIR SPRING AND THE VEHICLE IS ON THE GROUND, PRIOR TO AIRING THE SUSPENSION SYSTEM MAKE CERTAIN THE AIR SPRING LOCATOR IS INDEXED INTO THE UPPER AIR SPRING BRACKET PROPERLY, AND THE AIR SPRING IS FULLY SEATED ON THE SPRING TOP PAD. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PREMATURE AIR SPRING FAILURE, CAUSE PERSONAL INJURY, OR PROPERTY DAMAGE.

PRIOR TO AND DURING DEFLATION AND INFLATION OF THE FRONT AIR SUSPENSION SYSTEM, ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND AROUND THE SERVICE AREA, FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.

MODIFYING COMPONENTS DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORISATION FROM HENDRICKSON. DO NOT USE SUBSTITUTE OR REPLACEMENT COMPONENTS NOT AUTHORISED BY HENDRICKSON. USE OF MODIFIED, REWORKED, SUBSTITUTE OR REPLACEMENT PARTS NOT AUTHORISED BY HENDRICKSON MAY NOT MEET HENDRICKSON’S SPECIFICATIONS, AND CAN RESULT IN FAILURE OF THE PART, LOSS OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE. USE ONLY HENDRICKSON AUTHORISED REPLACEMENT PARTS.

PROCEDURES AND TOOLS A MECHANIC 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 JEOPARDISED BY THE METHOD OR TOOL SELECTED. INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED.

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Front ARB Installation The front ARB kit does not require any chassis drilling. 1. Proceed as follows: a. Place the bus over a working pit or raise off the floor. b. Chock the wheels of the vehicle where a working pit is utilised. c. Check the ride height and adjust where necessary. Ride height setting = 482 mm – shock absorber mounts – centre to centre. If vehicle is fitted with dual height control valves, follow adjustment procedure in technical publication “17730-234 PARASTEER™ Service Instructions” page 7 and 8. d. Ensure the ARB mounting points on the existing suspension and chassis structure are clean and free of any foreign material. e. Ensure the captured nut thread in the existing front chassis cross member is free of any foreign material. Clean the thread by using a tap to avoid any damage to the new hardware. f. Ensure that the vehicle’s front and rear ride height is check and corrected where necessary. g. Install the tower brackets to the front chassis cross member (pictured below). Ensure the bushes are lubricated on the inner surface sufficiently prior to installation. Do not set to torque at this point.

h. Install the angle brackets, facing inward, to the vacant mounting hole in the air bag mount bracket between the trailing arms (as pictured below). Do not set to torque at this point

i. Lubricate the lower ARB bushes on the inner surface only and position on the ARB with the lower tower brackets.

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j. Offer the ARB and tower mount brackets up to the lower tower mounting points (as pictured below).

k. Install the front ARB mounting hardware to the angle bracket attached to the airbag mount bracket (as pictured below). l. Locate the stepped nylon bushes to the ARB eye, on both sides. Place 3 x hardened washers, (part# 97022-002), as shown in the image below at item 1. Offer up the ARB to the mounting hardware and tighten the nut until nylon bushes begin to compress, then tighten nut by a further three revolutions.

m. Set all remaining hardware to torque. n. The front ARB is now fully installed (as pictured below).

o. Install new shock absorbers supplied in the kit and set to torque. p. Test drive for 5 km and recheck all hardware for torque.

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Rear ARB Installation 1. Proceed as follows: a. Place vehicle over a working pit or raise off the floor. b. Chock the wheels of the vehicle where a working pit is utilised. c. Ensure the ARB mounting points on the chassis and axle housing are clean and free of any foreign material. d. Drill the six holes in the underneath side of the chassis rails, three per side, refer to detailed drill pattern at enclosure 1. e. Attach the ARB mounting towers to the cross member and set to torque. Critical torque values are detailed at enclosure 3. f. Attach the cross member to the chassis rails and set to torque.

VEHICLE MUST BE FIRMLY SUPPORTED WITH JACK STANDS PRIOR TO SERVICING. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.

PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM, ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND AROUND THE SERVICE AREA; FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.

NOTE: See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system. g. Dump the air bags on the rear suspension. h. Verify all the air is removed from the system. i. Raise the chassis off the vehicle to remove load from suspension. j. Support the drive axle assemble prior to removing the U-bolts. k. Remove the U-bolts attaching the main support member to the axle housing. l. Install the 270 mm threaded stud to the lower axle clamp bracket with the bushes and washers. m. Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions prior to installing the U-bolts, refer to figure 1. n. Ensure that the threaded rod hardware is located in the correct position (lock nuts to the outside, narrow nuts to the inside). Figure 1

Quantity Item Description Part (Per Single Axle) M20 X 1.5 X 270 Threaded 1 98646-011 Two Rod 2 M20 X 1.5 Nut (U-Bolt) 97024-003 Sixteen 3 M20 Washer Narrow 98573-005 Eight Nylon bush Diameter 21 x 4 98573-004 Eight 56 5 Torsion Bar-Nut - Thin 98666-002 Four 6 Nut Lock - 3/4 Inch UNC 98666-003 Four

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o. Install the new U-bolts (do not include the lower ARB mounting plate at this time) and set to torque using Hendrickson torque socket 98825-004 (socket included in the kit) and following the U-bolt Torque Pattern at figure 9. p. Ensure the main support members (MSM) are correctly located prior to setting the U-bolts to torque. q. Evenly tighten U-bolt lock nuts to torque following the U-bolt torque pattern, refer to figure 8. Rap top of the U-Bolts and retighten to torque again. r. Install the four loose spacers (2 x left side and 2 x right side), part number 98496-003 to the rear of the U-bolts. s. Install the 2 x fabricated brackets part number 98639-014 to front U-bolts, 1 left side and 1 right. t. Install the lower ARB mounting plate, part number 98639-017, to the U-bolts. Install the remaining eight U-Bolt nuts (refer to figures 2 & 3) and set to torque. Figure 2 Figure 3

u. Lubricate the tower mount clamp bushes on the inside surface and attach the tower brackets to the crossmember as per figure 4. DO NOT set to torque. Figure 4

v. Lubricate the ARB tower mount bushes on the inner surface and offer the ARB up to the lower tower brackets and install the clamp brackets. DO NOT set to torque at this time.

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Figure 5

w. Install the upper ARB stop nut (thin), washer and bush to the threaded rod. x. Offer the ARB up to the threaded rod and attach the lower bush, washer and Nyloc nut as per figure 6.

Figure 6

y. Adjust the height of the ARB so that it is horizontal to the chassis rails at ride height. z. Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions. aa. Set the ARB mounting bracket hardware to torque, refer to figure 7.

Figure 7

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bb. The rear suspension ARB kit comes with Koni adjustable shock absorbers. Prior to installing the new shock absorbers, ensure that the shock absorbers are adjusted to the highest damping rate. cc. This is achieved by fully compressing the shock absorber then whilst holding the base, turn the top of the shock absorber clockwise (while pushing down gently) until you feel the locking pin lock into the adjuster slot. Rotate the top section of the shock absorber clockwise until it stops turning then back off approximately 10 mm. This is now the highest damping rate dd. . Install the shock absorbers and set to torque. ee. Reinflate air bags and ensure suspension ride height is to specification – 583 mm shock length, centre to centre.

Test Drive a. Test drive vehicle for 5 km.

b. Return the vehicle to the workshop.

c. Place vehicle over a working pit or raise off the floor.

d. Chock the wheels where a working pit is utilised.

e. Recheck all hardware for correct torque.

Figure 8 U Bolt Torque Pattern

NOTE: All hardware and U-bolt torque to be rechecked at 1600 km. Then follow normal maintenance intervals in accordance with the Hino RK1J Bus OEM literature.

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ENCLOSURE 1 TO: HINO RK BUS ARB MODIFICATION TECHNICAL BULLETIN 97117-142

RK BUS REAR SUSPENSION ARB DRILL PATTERN

Note: Dimensions are in Millimetres

RK BUS DRILL PATTERN – SIDE VIEW

RK BUS DRILL PATTERN – VIEWED FROM UNDERNEATH

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ENCLOSURE 2 TO: HINO RK BUS ARB MODIFICATION TECHNICAL BULLETIN 97117-142

HINO RK BUS PARAMAAX™ FRONT SUSPENSION TORQUE TABLE

3 2

4 1

Hendrickson Item Description Part No. Torque Nm Thread/Grade (a) (b) (c) (d) (e) 1. Nyloc Nut M20 97024-001 M20 X 2.5 * 2. Nut M 24 97071-001 M24 X 3 Lock (Class 10) 1055

3. Nut M 12 97715-001 M12 X 1.25 140 M12 X 1.25 X 70 mm LG 4. Hex Head Flange Bolt 98651-003 (Hino Part No SH562-3) 140 Note: 1. Torque Values listed above only apply if Hendrickson supplied fasteners are used. *. Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions

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ENCLOSURE 3 TO: HINO RK BUS ARB MODIFICATION TECHNICAL BULLETIN 97117-142

HINO RK BUS COMFORT AIR™ REAR SUSPENSION TORQUE TABLE

5 3 4

Hendrickson Item Description Part No. Torque Nm Thread/Grade (a) (b) (c) (d) (e)

1. Nut Lock 50765-000 7/8 Inch High 570

2. Nut Lock 97021-001 M16 X 2.0 310

3. Torsion Bar-Nut 98666-002 N/A 4. Nyloc Nut 98666-003 3/4 Inch UNC * 5. Nut Lock 97715-001 M12 X 1.25 140

Note: 1. Torque Values listed above only apply if Hendrickson supplied fasteners are used. *. Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions

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Parts Rear Suspension Hino RK Bus COMFORT AIR™ ARB

Item Part Description Qty 1 22962-002-H Washer Hardened - 7/8" 16 2 50765-000 Nut Lock - 7/8" UNF - High 16 3 97020-002 Bolt - M16 X 2 X 50 mm 6 4 97021-001 Coneloc Nut - M16 X 2.0(Class 10) 6 5 98373-003 Torsion Bar - Stud Bush 8 6 98573-004 Torsion Bar - Washer 8 7 98666-002 Torsion Bar - Nut 4 8 98666-003 Nut 3/4 UNC Nyloc Thin 4 9 98979-001 Stabiliser Bar - Steer Axle 1 10 97077-009 Crossmember 1 11 97715-001 Nut - M12 X 1.25 16 12 98408-010 U-Bolt - 7/UNF 4 13 98496-003 Spacer, Ø22 U-Bolt 4 14 98583-066 Shock Absorber, Adjustable, COMFORT AIR™ 2 15 98594-020 Bracket - (Hino Part No. S4886-71370) 4 16 98594-006 Bracket - (Hino Part No. S4880-91190) 4 17 98594-007 Plate Antiroll Bar Mtg 2 18 98639-017 Plate Fabrication, Antiroll Bar, U-Bolt 2 19 98639-014 Spacer Fabrication, Antiroll Bar, U-Bolt 2 20 98646-011 Stud - 3/4" UNC X 270 mm Long 2 21 98651-003 Hex Flange Bolt M12 X 1.25 X 70 mm Lg (Hino Part No SH562-3) 16 22 98982-006 Bush - (Hino Part No. S4886-11680) 8 23 98825-004 1-5/16" Socket, 3/4" Drive, 175 mm Deep 1

NOTE: Hino supplied part numbers are shown in Red.

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Parts Front Suspension Hino RK Bus PARASTEER™ ARB

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Item Part Description Qty 1 97022-002 Washer - Hardened Dia 20 10 2 97023-008 Bolt - M20 X 2.5 X 110 mm 2 3 97024-001 Nut - M20 X 2.5 2 4 97070-006 Bolt -M24 X 3 X 220 mm (G-10.9) 2 5 97071-001 Nut - M24 X 3.0 Conelock Class 10 2 6 97072-001 Washer - Hardened Dia 24 4 7 98373-003 Torsion Bar - Stud Bush 4 8 98979-002 Antiroll Bar 1 9 97715-001 Nut - M12 X 1.25 8 10 98583-060 Shock Absorber 2 11 98594-007 Plate Antiroll Bar Mtg 2 12 98594-006 Bracket - (Hino Part No. S4880-91190) 4 13 98594-020 Bracket - (Hino Part No. S4886-71370) 4 14 98639-007 Bracket - Antiroll Bar 2 15 98651-003 Hex Flange Bolt M12 X 1.25 X 70 mm Lg (Hino Part No SH562-3) 16 16 98982-006 Bush - (Hino Part No. S4886-11680) 8 17 98982-007 Bush - Antiroll Bar 2

NOTE: Hino supplied part numbers are shown in Red.

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Revision Date Page - Paragraph Remarks Rev E July-2013 Page 10 - Para 1 Added - adjusting rear shock to highest damping rate prior to install. Rev F Aug-2013 Page 9 - Para X Added - Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions Rev F Aug-2013 Page 12, 13 – Note * Added - Tighten nut until nylon bushes begin to compress, then tighten nut by a further three revolutions Rev F Aug-2013 Page 8 – Para R Install the four loose spacers (2 x left side and 2 x right side), part number 98496-003 to the rear of the U-bolts. Rev F Aug-2013 Page 8 – Para S Install the 2 x fabricated brackets part number 98639-008 to front U-bolts, 1 left side and 1 right side. Rev I Dec-2014 Page 14 Rear ARB Part list Changed shock absorber part number from 98583-061 to 98583-066. Added Hino part number, marked in red. Added part number for U-Bolt socket. Rev I Dec-2014 Page 14 Front ARB Part list Added Hino part number, marked in red. Rev L Jun-2017 Page 8 – Para T Evaluation of improved ARB Bracket ECP 11068. Rev L Jun-2017 Page 14 Rear ARB Layout Revise part descriptions Rev L Jun-2017 All Spelling and format Rev M Jan-2019 1, 2, 13, 14, 15, 16 Update from RD numbers ECN 11122. Rev N Aug-2020 14 Update washer 98651-003-H, ECN 11744

Actual product performance may vary depending upon vehicle configuration, operation, service and other factors. All applications must comply with applicable Hendrickson specifications and must be approved by the respective vehicle manufacturer with the vehicle in its original, as-built configuration. Contact Hendrickson for additional details regarding specifications, applications, capacities, and operation, service and maintenance instructions.

Information contained in this literature was accurate at the time of publication, Product changes may have been made after the publication date that are not reflected here.

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