CHASSIS PREPARATION AND SUSPENSION ASSEMBLY GUIDE · 4. install rebound cable to secure the...
Transcript of CHASSIS PREPARATION AND SUSPENSION ASSEMBLY GUIDE · 4. install rebound cable to secure the...
AN
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Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 1 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
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FINISH
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33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltd's written permission
CHASSIS PREPARATION AND SUSPENSION ASSEMBLY GUIDE
2. GENERAL LAYOUT
3. WELD ON COMPONENTS
4. INSTALLATION / FITMENT
5. RECOMMENDED TORQUE SETTING
6. HYDRAULIC / PNEUMATIC / W IRING
7. ALIGNMENT
8. PARTS LIST
REV DESCRIPTION ECN NAME DATE
5 New adjuster design 1630 AJ 29/01/2018
4 M inimum chassis height 150 was 100 1580 AJ 13/04/2016
3 CM ATX M INIMUM WHEEL SPACING 1571 AJ 15/12/2016
2 MODEL UPDATE 1550 AJ 24/09/2016
1 RELEASED FOR PRODUCTION 1520 AJ 16/09/2016
AIRBAG RIDE HEIGHT
B
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BD
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Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 2 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
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33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this drawing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty
TOOL NO. DESCRIPTIONNATURAL
880
WHEEL BASE
800 MIN
WHEEL
MOUNTING
FACE
HINGE TOE ADJUSTER
S IDE TOWARDS
CHASSIS OUTER
( HOR IZONTAL SLOT )
HINGE AND SPRING TOP MOUNTS
ARE POSIT IONED ON CROSSMEMBERS
RELATIVE TO CHASS IS OUTER WALL TO
OBTAIN DESIRED C/F
C/F
NOTE FOR TANDEM AXLES
MAX ATM SPECIFIED @ 10% DRAWBAR WEIGHT
TH IS IS A CLOSE COUPLED, NON-LOAD SHARING
SUSPENSION. ENSURE THAT THE LOAD ON THE AXLE
GROUP DOES NOT EXCEED THE REQUIREMENTS OF THE
NATIONAL CODE OF PRACTICE (VSB 1 - BUILD ING SMALL
TRAILERS)
LUBRICATION
GREASE BORE AND FLANGE OF POLYURETHANE BUSHES
DURING INSTALLATION AND REGULARILY DURING SERVICE
US ING AUTOMOTIVE BEARING GREASE. INJECT THROUGH
GREASE N IPPLE UNTIL GREASE STARTS COMING OUT
BETWEEN HINGE AND BUSH.
SPR ING KITS
Rating/ATM (kg) Spring type AXLES
2200 COIL SINGLE
2600 COIL SINGLE
2800 COIL SINGLE
3700 COIL TANDEM
4500 COIL TANDEM
< 2800 AIR SINGLE
< 4500 AIR TANDEM
545 TYP
SUPPORTING CROSSMEMBERS
428 TYP
BUMP STOP MOUNT= WHEELBASE - 645
155 M IN
216+ 60
80-
AT RATED LOAD
OPTIONAL SHOCK
GUARD
HYDRAULIC BRAKE
OPTIONELECTRIC BRAKE
OPTION
CO IL SPRING
OPTION
864 561
ENSURE SHOCK
RESEVOIR IS
MOUNTED AWAY
FROM WHEEL
GENERAL LAYOUT
150 M IN
50 ONLY
RECOMMENDED
STIFFENER BEAM
FOR HINGE RHS
50x50x3 M IN
<<< FRONT
55
M INIMUM
WHEEL
SPACING
75
DETAIL B
P
DETAIL B
A
B
C
DD
C
B
A
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Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 3 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltd's written permission
CF
6
6
X
CHASSIS
OUTER WALL
HINGE RHS
OUTER FACE
6 3x50
6 3x50
CHASSIS
OUTER WALL
WELD-ON COMPONENTS
1. POSITION MOUNTSENSURE THE CHASSIS MEETS THE REQUIREMENTS DETAILED BELOW
ENSURE ALL REQUIRED CROSSMEMBERS AND BRACINGS ARE FITTED
POSITION BUMP STOP MOUNTS AND WELD AS SPECIF IED
2. HINGESCHECK POSIT ION OF THE HINGES
FOR THE REQUIRED CHASSIS TO WHEEL FACE
AND WELD AS SPECIF IED
DO NOT WELD
THIS SURFACE
X
545
CROSSMEMBERS
428
BUMP STOP
ALL SUPPORTING
CROSSMEMBERS
4mm MIN WALL
THICKNESS100 M IN
RHS HEIGHT
90°
TO ENSURE
ACCURATE
ADJUSTMENT
6
6
3. TOP SPRING MOUNTCHECK POSITION OF THE HINGES
FOR THE REQUIRED CHASS IS TO WHEEL FACE
AND WELD AS SPECIFIED
SUPPORT BRACE
50x50x3
150 M IN
50 M IN
50 W IDTH
RHS ONLY
6
6
6
6
OPTIONAL ANTI-ROLL BAR
MOUNTING PO INTS
REFER 33ATX-AR-001
FOR POS ITIONING INSTRUCTIONS
6
6
REFER
33ATX-AR-001
WELD ON POSIT ION FROM OUTER CHASS IS WALL (mm)
CF X ( ELECTRIC ) X ( DISC )
250 MAX 0 7
225 25 32
200 50 57
175 M IN 75 82
ALL CHASSIS RAILS AND SUPPORTING CROSSMEMBER SECTIONS
MUST BE RHS 100x50x4 M INIMUM
CROSSMEMBERS MUST
BE FULL W IDTH
X = 250 - CF
SPRING MOUNT AND
H INGE RHS MUST BE
ALIGNED
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352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
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A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 4 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltds written permission
2. ASSEMBLE ARMLIGHTLY GREASE THE INSIDE FACES OF
THE HINGE PLATES AND SLIDE THE
CONTROL ARM UP INTO POSIT ION
INSTALLATION / FITMENT
1. CONTROL ARM BUSHES
GREASE AND ASSEMBLE
BUSHES AND END WASHERS
INTO CONTROL ARM
TOE ADJUSTER
IN NEUTRAL (VERTICAL)
CAMBER ADJUSTER
IN NEUTRAL (HORIZONTAL)
[ 3 ]
SHOCK
ABSORBER
[ 4 ]
REBOUND
CABLE
APPLY GREASE
4. LOCK ADJUSTER BOLTS1. LOCK CAMBER ADJUSTER HORIZONTALLY
2. LOCK TOE ADJUSTER VERTICALLY
5. SPRINGS AND SHOCKS
FOLLOW INSTALLATION ORDER
1. USE TOP ADAPTOR FOR CO IL SPRINGS
2. INSTALL SPR ING, USE SUPPLIED F ITT ING FOR AIRBAGS
3. INSTALL SHOCK ABSORBER TO CONTAIN THE SPR ING
4. INSTALL REBOUND CABLE TO SECURE THE SUSPENS ION ASSEMBLY
5. STONE GUARD, BUMP STOP, ANT I-ROLL BAR AND OTHER OPTIONS
USE GREASE PORT TO FILL
HINGE CAVITY ONCE HINGE IS
FULLY ASSEMBLED AND TORQUED
[ 2 ]
SPRING
AIR / COIL
3. HINGE ASSEMBLY1. INSERT THE H INGE SPINDLE THROUGH THE ASSEMBLY FROM THE OUTER H INGE PLATE
2. ASSEMBLE CAMBER ADJUSTER, ADJUSTER LOCK ING BOLTS AND H INGE NUT
OUTER H INGE
PLATEINNER HINGE
PLATE
HINGE NUT
200 N.m ADJUSTMENT
LOCKING BOLT
50 N.m
CAMBER
ADJUSTER
TOE
ADJUSTER
INSERT FROM HERE
[ 5 ]
ANTI ROLL
BAR
REFER PAGE 8 (PARTS LIST)
FOR EXPLODED ASSEMBLY
[ 1 ]
TOP ADAPTER
COIL SPRINGS ONLY
BUMP STOP
AIRBAG BOLTS
BUMP STOP
BC
A
B
C
DD
C
B
A
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Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 5 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltds written permission
RECOMMENDED TORQUE SETTINGS
200 N.m 3/4UNF
HINGE NUT
50 N.m M10
DAMPER GUARD
BOLTS
50 N.m M10
ADJUSTER
LOCK BOLTS
90 N.m M12
DAMPER
BOLTS
90 N.m M10
REBOUND
STRAP
BOLTS
30 N.m M8
BUMP STOP
BOLT
50 N.m M10
ANTI ROLL BAR
MOUNTING
BOLTS
90 N.m M12
DAMPER GUARD
SHOCK BOLT AND
SPACER
50 N.m M10
ANTI ROLL BAR
TOP LINK BOLT
90 N.m M12
ANTI ROLL BAR
BOTTOM LINK BOLT
ALL FASTENERS SHOWN ZINC PLATED CLASS 8.8 ONLY
50 N.m . M10
TOP COIL SPRING MOUNT
16 N.m . 3/8UNC
AIRBAG BOLT & NUT
CABLE ROUTING
DETAIL OF LEVER
AM
CABLE ROUTING
BE
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B
C
DD
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B
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Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 6 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltds written permission
HYDRAULIC / PNEUMATIC / W IRING
ROUTE / SECURE AIR LINE TO
SPRING MOUNT CROSSMEMBER
TO AIR CONTROL
R IGHT
TO AIR CONTROL
LEFT
PARK BRAKE LEVER
SHOWN FOR ILLUSTRATION
PURPOSES ONLY
USE CONDUIT CHANNEL
TO ROUTE / SECURE
ELECTRIC BRAKE W IRING
TO CONTROL ARM
TO FRONT AXLE
R IGHT AIRBAG
TANDEM ONLY
TO FRONT AXLE
LEFT AIRBAG
TANDEM ONLY
ENSURE W IRING / CABLES
ARE PROPERLY SEATED
AND SECURED INSIDE
THE ROUTING CHANNEL
( USE ZIP/CABLE TIES
THROUGH SLOTS )
ROUTE BRAKE CONTROL
LINES UP TO CHASSIS
CLOSE TO CROSSMEMBER
TO M IN IM IZE FLEXURE
FROM SUSPENSION
TRAVEL
TO ELECTRIC / HYDRAULIC
BRAKE POWER
ALL BRAKE W IRING / HYDRAULIC LINES STRICTLY TO VSB1 AS
PER 14 & 15.2 (ADR 42/04-9, 38/02-5)
▼ FRONT▼
ENSURE THE AIR LINE IS SECURED
TO THE CHASSIS TO M INIM ISE THE MOVEMENT
LEVER BEND AT
TOP OF ARM
AIR FITTING DIAGRAMS
LOCATED IN AIR KIT DRAWINGS
TYPICAL ADJUSTMENT
TYPICAL ADJUSTMENT
AT
AT
TYPICAL ADJUSTMENT AV
AW
AY
BK
A
B
C
DD
C
B
A
1 2 3 4 5 6
5 61 432
E
F F
E
Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 7 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltds written permission
ALIGNMENTWHEEL ALIGNMENT PROCEDURE
1. ENSURE THE TRAILER IS FULLY LOADED AND ON A FLAT
SURFACE, MOVE THE TRAILER BACKWARDS AND FORWARDS
TO ELIM INATE TW IST IN THE WHEELS.
MEASUREMENT
FOR TOE MEASUREMENT
2. PLACE A STRAIGHT EDGE ACROSS THE WHEEL, EDGE OF RIM
OR DRUM FACE, THEN MEASURE THE DISTANCE FROM THE
STRAIGHT EDGE TO THE CHASSIS RAIL. ABOUT 800MM APART
(WHEELS ON A SINGLE OR TANDEM FRONT AXLE SHOULD BE
ADJUSTED TO HAVE ±2MM TOE-IN . WHEELS ON TANDEM REAR
AXLE SHOULD MEASURE PARALLEL FROM THE CHASSIS RAIL.)
FOR CAMBER MEASUREMENT
3. IT IS RECOMMENDED TO USE A DIGITAL SPIR IT LEVEL TO
MEASURE VERTICALLY ACROSS THE WHEEL RIM OR DRUM FACE.
ADJUSTMENT
4. LIFT THE VEHICLE TO UNLOAD THE SUSPENSION. DO NOT
CLIMB UNDER A VEHICLE ONLY SUPPORTED BY JACKS,
ENSURE VEHICLE SAFETY STANDS ARE USED.
5. LOOSEN THE HINGE NUT.
6. REMOVE THE LOCKING BOLT ON THE ADJUSTER.
7. TURN THE ADJUSTER IN THE DIRECTION REQUIRED AS PER
THE ADJUSTMENT DIAGRAMS AND ALIGN W ITH NEAREST BOLT
HOLES. USE BOTH COARSE AND FINE ADJUSTMENT HOLES TO
FIND OPTIMAL ADJUSTMENT POSITION.
8. REPLACE THE LOCKING BOLT AND NUT BEFORE REPEATING
ON NEXT ADJUSTER.
9. WHEN ADJUSTMENT IS COMPLETED, TIGHTEN AND TORQUE
ALL ADJUSTER LOCKING BOLTS. (SEE TORQUES SHEET)
10. TIGHTEN AND TORQUE HINGE NUTS. (SEE TORQUES SHEET)
11. LOWER THE VEHICLE TO LOAD THE SUSPENSION AND
MEASURE THE ALIGNMENT AGAIN TO CONFIRM SETTINGS
HAVE BEEN ACHIEVED.
12. IF THE NECESSARY ALIGNMENT HAS NOT BE ACHIEVED,
REPEAT FROM STEP 4
CAMBER ADJUSTERINNER H INGE ADJUSTER
TOE ADJUSTMENTOUTER HINGE ADJUSTER
0° - 0.5°
NEGATIVE
FINE ADJUSTMENT
APPROXIMATELY 0.1°
COARSE ADJUSTMENT
APPROX IMATELY 0.5°
UP
NEGATIVE
POSITIVE
DOWN
GENERAL TOE SETTINGS
FRONT: 0° TO 0.2° TOE IN
(0 TO 3mm)
REAR: 0° OR 0mm
198
200
GENERAL CAMBER SETTINGS
FRONT: 0° TO 0.5 ° NEGATIVE
HINGE PLATE
COARSE ADJUSTMENT
±0.5° (APPROX ±6mm)LOCKABLE ADJUSTER
FINE ADJUSTMENT
±0.1° (APPROX ±1.5mm)
FRONT
EXAMPLE
EXAMPLE
ACTUAL DIMENSIONS
MAY VARY DEPENDING
ON CHASSIS TO FACE
DESCRIPTIONPART NUMBERQTYITEM
CM ATX VC EL AXLE KIT33ATX-VC-E11
CM XT G6 SUBFR KIT WO33S-851011,3
CM XT G6 SHOCK SUBFR33S-840021,3,1
CM ATX G6 HINGE33S 820021,3,3
A - BUMP STOP MOUNT33S 841021,3,4
L - ATX BADGE33S 805621,5
ATX LEFT CONTROL ARM ( ELECTR IC / HYDRAULIC )33S 8810L / 33S 8820L11,6
ATX RIGHT CONTROL ARM ( ELECTRIC / HYDRAULIC )33S 8810R / 33S 8820R11,7
PLAST IC END CAP ATX 7533S 21921,13
CM ATX SHOCK GUARD KIT33C 02211,19
ATX HINGE SP INDLE AXLE K IT33ATX HK 0111,20
P - CM XTG6 HINGE BUSH33S 801941,20,1
L - HINGE SLIDE WASHER33S 804241,20,2
A - LOCKABLE ADJUSTER33S 831021,20,3
A - HINGE SP INDLE33S 830021,20,4
NUT 3/4 UNF NYLOC60-N-3/4-UNF-NYL21,20,5
NUT ZINC NYLON INSERT M1060-N-M10NYL41,20,7
BOLT HEX 8.8 M10x40 Z/P60-B-M10x4041,20,8
M46 BLACK 46mm S INGLE SHOCK KIT33C 01811,21
CM ATX RB STRAP KIT33C 01711,22
CM ATX BUMP STOP K IT33C 02111,23
SPRING KIT ( COIL / AIR )33ATX-CC / 33ATX-AK11,24
GREASE NIPPLE DUST COVER60-M-GN-COV21,25
GREASE NIPPLE M660-M-GN-M621,26
CM ATX ANT-ROLL BAR KIT (OPTIONAL)33ATX AR28
A
B
C
DD
C
B
A
1 2 3 4 5 6
5 61 432
E
F F
E
Cruisemaster Australia Pty Ltd
352b BILSEN ROAD, GEEBUNG, QLD 4034, (07) 3624 3800
DO NOT SCALE
A3PART NO
DRAWN
DATE DRAWN
APPROVED
CHECKED
CRUISEMASTER ATX SUSPENSION
AB
13/04/2016
AB
DvD 8 of 8 REMOVE SHARP EDGES ALL DIMENSIONS IN M ILLIMETERS
TITLE
Unless otherw ise stated
DIM TOL
0
0.0
0.00
±
±
±
0.5
0.2
0.05
FINISH
MASS
VOL
MATER IAL
N/A
N/A
33ATX
SUPPLIER CODE
A3-1 3.2MACHINEDThe copyright in this draw ing and any information or descriptive matter set out hereon is the property of Cruisemaster Australia Pty Ltd and must not be disclosed loaned copied or used for manufacturing tendering or for any other purpose without Cruisemaster Australia Pty Ltds written permission
PARTS LIST
1,21
1,3,3
1,3,1
1,24
1,19
1,3,4
1,23
1,7
1,5
1,13
1,20,8
1,20 ,51,20,3
1,20,7
1,6
1,251,26
1,20,1
1,20,2
1,20,41,22
8
2x 33SA-AB 0044-V
ELECTRIC BRAKE KIT W ITH COIL SPRING SHOWN
33S 8820L/R
HYDRAULIC BRAKE
CONTROL ARMS
ANTI-ROLL BAR KIT
OPTIONAL