Installation and Service Manual - [ · PDF fileTable of Contents Page Description Page SECTION...

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Installation and Service Manual

The Group

Disclaimer

The author and publisher have made their best efforts to prepare this manual, and the information contained in this manual is current at time of printing (as specific at the later section of this sheet). However, TMC’s policy is one of continuous development. We therefore reserve the right to change or modify the specifications without prior notification. No part of this manual may be stored in a retrieval system, transmitted, or reproduces in any way, including but not limited to photocopy, photograph, magnetic or other record, without the prior agreement and written permission of the author and its respective company. TMC and the TMC logo are trademarks of TMC Axle Manufacturing Sdn. Bhd. in Malaysia and also TMC branches at other countries.

Versioning

Version Number: v 1.0.0 Version Date: November 04

Table of Contents

Page Description Page

SECTION I -TMC Axle Installation and Service Manual 6 Axle Installation 6

Alignment 7 General Welding Recommendations 8 Spring Chair Mounting 9

Hub, Bearings and Seal 10 Hub, Bearings and Seal Removal 10 Bearing Inspection 12 Wheel Seal Installation 13 Bearing Installation 13 Bearing Adjustment (Castellated Single Nut - Parallel Spindle) 14 Bearing Adjustment (TMC Double Lock Nut - Parallel Spindle) 14 Filling Hub with Lube 15

Brakes 16 Brake Components 16 Brake Shoe Removal 16 Brake Shoe Installation 18 Slack Adjuster Removal 19 Slack Adjuster Installation 20 Camshaft and Camshaft Bearing Removal 24 Camshaft and Camshaft Bearing Installation 26 Brake Adjustment 27 ABS Sensor Replacement 28 ABS Sensor Installation 28

Troubleshooting 29 Troubleshooting Guide 29

Specifications and Maintenance 30 Torque Chart 30 Recommended Inspection Schedule 31

First Service 31 After first 5000 km 31 Every 5,000 km or Once a Month (Whichever Comes First) 31 Every 25,000 km or 4 Months (Whichever Comes First) 31 Every 100,000 km or 1 Year (Whichever comes first) 31 Every 300,000 km or 3 Years (Whichever come first) 31

Important Torque Settings 32 Axle Part List 33

Spare Part List 33

SECTION II - TMC Fifthwheel Coupler Service Manual 35 Fifthwheel Operations 36

Instructions 36 Fifthwheel Maintenance 37

Weekly and New Couplings 37 Every 5000km or monthly (Whichever Comes First) 37

Table of Contents


Troubleshooting 38 Troubleshooting Guide 38

Fifthwheel Part List 39 Spare Part List 39

SECTION III - TMC Landing Gear Service Manual 40 Landing Gear Operations 41

Installation 41 Operational Instructions 41 Maintenance 41

Landing Gear Part List 42 Spare Part List 42

SECTION IV - TMC CS Mechanical Suspension Service Manual 43 Installation 44

Installation of Suspension Hangers 44 Installation of Axle Seats, (Spring Seats) 44 Assembly of Torque Arms 45 Final Assembly 45 Axle Alignment and Adjustment Procedure 46

Service 47 Recommended Service Schedule 47

First Service 500 km or on Delivery: 47 Every 10,000km: 47 Every 50,000 km or Annually: 47

Equaliser and Equaliser Bushes - Assembly 48 General Welding and Repair Notes 48

Specifications and Maintenance 49 Torque Settings Chart 49

CS Mechanical Suspension Part List 50 Spare Part List 50

SECTION V - TMC 11T Air Suspension Service Manual 51 Installation 52

TMC 11T Air Suspension Installation Instructions 52 Recommended Installation Procedure 52 Final Assembly 53 Axle Alignment and Adjustment Procedure 54 Levelling Valve Installation 56

Service 57 Recommended Service Schedule 57

On Delivery or at 500 km: 57 Every 25,000km or Quarterly: 57 Every 100,000 km or Annually: 57

Table of Contents


Replacement of Suspension Airbags 58 Shock absorber replacement 58 Levelling Valve Adjustment 59

Specifications and Maintenance 60 Recommended Torque Settings 60

11T Series Air Suspension Part List 61 Spare Part List 61

As TMC’s policy is one of continuous development. We therefore reserve the right to change or modify the specifications without prior notification.

SECTION I - TMC Axle Installation

and Service Manual

Axle Installation

Axle Installation


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Alignment It is the responsibility of the axle installer to properly align the axle. Alignment must meet the requirements regarding squareness to the vehicle center line, axle-to-axle dimensioning and parallelism between axles. Always follow industry standard alignment practices published by TMC (RP 708)

Axle Installation


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General Welding Recommendations In order to prevent possible twisting and distortion of the axle beam due to excessive welding, it is recommended that the axle be secured in an assembly fixture. There are several steps that can be taken to eliminate axle failures due to improper welding of axle components:

Welding on the top and/or bottom of the trailer axle beam can result in stress risers (cracks) and premature failure of the axle beam.

• Welds may be horizontal or vertical of center line at both the front and rear of the axle, but under no condition are welds to be made in the “no weld” area marked in the adjacent illustration. The heat of welding and subsequent cooling causes the metal adjacent to the welding to become brittle. If this condition occurs in the high stress areas at the top and bottom of the axle, premature cracking may occur. Mounting can also be achieved by directly welding upper and lower brackets, etc., to the axle.

• The axle and all components being welded should be at a temperature of at least 60°F (15°C).

• All components welded to the axle should have close fitting surface-to-surface contact to avoid excessive welding of gaps on the axle.

• Clean the area to be welded to remove any dirt, grease or other material that may affect weld quality.

• Use a welding rod which meets American Welding Society Standards #E8018C-2 with a 3/16" maximum diameter.

• Do not break arc at ends of fillet, but back electrode up to fill.

WARNING

Axle Installation


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Do not attach the welder ground cable to the axle so that a bearing is between area and ground point. Electric arcing can damage a bearing that is between the weld and the ground.

• Attach the welder ground cable to a component mounted on the axle such as the brake spider, air chamber brackets or camshaft support brackets. The ground cable attachment should be tight and clean.

• Set amperage and voltage per recommendation by electrode manufacturer. • Do not test arc on axle or brackets as this can result in notches or stress risers.

Spring Chair Mounting Extreme care must be taken while locating the spring chairs on a TMC axle to avoid problems like toe-in, toe-out and build-up of torsional stresses in the springs and suspension. Follow these guidelines to ensure proper installation of the spring chairs.

• Load bearing surfaces must be parallel to each other within 3/46" in 5".

NOTE: Please follow installation requirements of the suspension from manufacturer for parallelism.

• Preheat the spring chairs prior to welding in order to minimize local hardening. Weld to axle using 3/16" rod. Spring chairs (bottom plates) may also be mounted on underside of axle.

CAUTION

Hub, Bearings and Seal


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Hub, Bearings and Seal Removal

Always wear eye protection when working on an axle. 1. Release the breaks. 2. Using a suitable socket (Part No. EUE-

1597A), remove the hubcap. NOTE: The socket used to remove the hubcap is also used to remove the single axle nut.

WARNING



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3. On axle with a single axle nut: • Remove the cotter pin from the axle

nut. • Remove the axle nut and washer from

the spindle. 4. On axle with the double lock nut:

• Remove the outer axle nut and spacer tab washer.

• Bend the lock washer tab securing the adjustment nut back away from the nut.

• Remove the adjustment nut, lock washer and slotted washer from the spindle.

5. On axle with industry standard double lock

nut: • Remove set screw from the spindle tab

washer. • Remove the outer jam nut and the spindle tab washer • Remove adjustment nut.

6. Remove the hub washer from the spindle. 7. Remove the outer hub bearing from the spindle.



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Do not hit steel parts with a steel hammer. Parts can break, and flying fragments can cause injury. 8. Remove the hub from the spindle. It may

be necessary to tap the hub with a soft mallet to release the hub seal from the spindle.

9. Remove the inner hub bearing from the spindle or the inside of the hub.

Do not use a chisel to cut the seal. The shoulder can be damaged, resulting in a leak. 10. Remove the wheel seal from the spindle by gently tapping with a soft mallet. You can also use an

appropriate pry bar to pry the seal off the spindle, being not to gouge the shoulder. NOTE: The seal may have come off the spindle when the hub was removed.

Bearing Inspection

Please thoroughly clean bearing surfaces and cones. Do not mix a synthetic base grease or oil with an organic/mineral base lubricant. Do not spin fry bearing cones with compressed air. Bearing damage may result. After removing the axle hub, clean excess grease from the bearing cones. Inspect bearing cones for damaged rollers. Inspect bearing cups for damage to raceway. If any damage is found, replace the affected cone and cup as a set.

CAUTION

CAUTION

WARNING



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Wheel Seal Installation The following instructions apply to installing wheel seals (Part No. TMC 2004-800723) in new TMC axle beam assemblies and servicing TMC complete axle assemblies.

To avoid damaging the wheel seal, support the hub and drum until the outer bearing cone and adjusting nut are installed. 1. If installing the seal on a new TMC axle beam assembly, remove the protective coating from the

bearing spindle threads, wheel seal surfaces and cotter pin holes. If installing the seal in an in-service axle, go to Step 2.

2. Remove all dirt, chips and hanging burrs from wheel or hubcap, making sure they are clean and dry.

Never install the seal in the hub and then force it into the axle spindle by tightening the axle nut. 3. Using seal installation tool (552-5239), place seal on spindle with printing "FLUID SIDE" facing

the end of the spindle. Tap lightly to seat seal. 4. Rotate the seal installation tool in V4-turn intervals until the seal is properly seated with the metal

face of the seal flush with the inner shoulder of the axle spindle. 5. Check for burrs or chips after installation.

Bearing Installation

Wheel seals should be installed before performing the wheel bearing adjustment procedure. 1. Coat inner bearing with lubricant recommended for your application. Install inner bearing. 2. Install wheel, taking care not to unseat or bend the oil seal. 3. Coat outer bearing with lubricant recommended for your application. Install outer bearing. 4. Slip on axle washer.

CAUTION

CAUTION

CAUTION



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Bearing Adjustment (Castellated Single Nut - Parallel Spindle)

Wheel seals should be installed before performing the wheel bearing adjustment procedure. 1. Install bearings and wheel or hub on axle. 2. Install bearing tab washer. 3. Install wheel bearing adjusting nut. Screw nut

against the bearing tab washer. 4. Make sure the brake shoes do not drag on the

brake drum. 5. Tighten the adjustment nut to 125 ft-lbs (169

Nm) while rotating the wheel. NOTE: Rotate the wheel in both directions to correctly position the bearings. 6. Back off the adjustment nut so that the cotter pin can be installed in the first hole. 7. Install cotter Din and lock in place.

Bearing Adjustment (TMC Double Lock Nut - Parallel Spindle)

Wheel oil seals should be installed before performing the wheel bearing adjustment procedure. 1. Install bearings and wheel or hub on axle. 2. Install bearing tab/slotted washer. 3. Install lock washer with keyway tab pointing outboard. (Make sure the two alignment tabs

engage slots in the axle washer.) 4. Install wheel bearing adjusting nut. Screw nut against lock washer. 5. Tighten the adjustment nut to 125 ft-lbs (169 Nm) while rotating the wheel. NOTE: Rotate the wheel in both directions to correctly position the bearings. 6. Back off the adjustment nut to the first available nut slot/lock washer tab combination. 7. Bend one lock washer tab into the axle nut slot to prevent the nut from backing off. 8. Install the spacer tab washer. 9. Install the second axle nut and tighten to 250-300 ft-lbs (339-406 Nm)

CAUTION

CAUTION



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Filling Hub with Lube

Do not overfill the hub. 1. Fill the hub with the specified lubricant

(oil), through the hole in the hub cap, to the FILL mark. The installer should consult the hub manufacturer's specifications for lubricant capacity.

2. Allow the oil to flow through the bearings and level off.

3. Insert the rubber plug into the hole in the

hub cap. NOTE: With axles equipped with a centralized tire inflation system, like Pressure Systems International, a vented hubcap must be used. NOTE: If using semi-fluid grease, TMC recommends using an electronic metering device to accurately reflect fill levels.

CAUTION

Brakes


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Brakes

Brake Components

Brake Shoe Removal 1. Manually release the brakes. 2. Remove the brake drum. 3. Remove the two brake retaining springs.

Heavy- duty brake spring pliers (Part No. E-2656) are available from TMC AXLE MANUFACTURING SDN BHD.

Brakes


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4. To remove the brake shoes: • Press down on the lower brake shoe to

disengage it from the anchor pin. • Move the lower shoe to the side of the

anchor bracket. • Lift the upper and lower shoes (still

connected by brake return spring) from the anchor plate.

5. Remove the anchor pins. If equipped with

a drive pin (P- Model brakes), remove this pin first. A brake shoe anchor pin press (Part No. E-2654) is also available from our TMC MANUFACTURING SDN BHD.

6. Remove the anchor pin bushing, if necessary.

7. Insert a screwdriver into the brake shoe and press the retaining tab of the cam roller clip while gently pulling the roller.

8. While maintaining pressure on the roller, turn the brake shoe over and Insert a screwdriver into the brake shoe and press the retaining tab of the opposite cam roller clip while gently pulling the roller.

9. Remove the roller and dip from the brake shoe. 10. Remove the roller from the dip and inspect for damage. NOTE: Inspect brake shoes and drum for wear. Follow brake manufacturer guidelines for minimum brake shoe thickness and maximum brake drum Inner diameter. A general guideline for replacing brake shoes is when the lining thickness is 1/4 Inch or less, or when the lining rivets have begun to contact the drum.

Brakes


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Brake Shoe Installation 1. Install the cam roller into the roller dip. 2. Install the roller and clip into the brake shoe. 3. Install the anchor pin bushings (if removed) in the spider. A brake shoe anchor pin press (Part No.

E-2654) is available from TMC AXLE MANUFACTURING SDN BHD. 4. Coat anchor pins completely with grease (STK0139220Lubriplate #630AA) and install anchor pins. 5. Connect the brake return spring to the

brake shoes. 6. Position the roller of the upper spring to

the brake shoes. 7. Position the lower brake shoe in the cam

head, and then place the other end of the hoe against the anchor pin.

8. Install the two brake retaining springs. Heavy- duty brake spring pliers (Part No. E-2656) are available from TMC AXLE MANUFACTURING SDN BHD.

9. Make sure the brake linings are clean. 10. Install the brake drum. 11. Adjust the brakes as described in this

manual. 12. Lubricate the camshaft bearings with the

specified grease.

Brakes


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Slack Adjuster Removal 1. Remove the cotter pin that secures the

slack adjuster/brake chamber clevis pin. Remove the clevis pin.

2. Remove the snap ring and washer that

secure the slack adjuster to the camshaft. Remove the slack adjuster.

Brakes


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Slack Adjuster Installation Haldex Automatic Slack Adjuster 1. Apply an even coat of anti- seize compound

(STK.70033) to serrated or splined surface of camshaft.

2. Install adjuster onto camshaft with adjusting nut away from brake chamber bracket.

3. Once adjuster is secured on camshaft and brake chambers have been installed, rotate adjusting nut clockwise until clevis holes line up with hole in adjuster arm. Distance from brake chamber bracket o clevis hole is approximately 7.62 inches for 16Vi Inch brakes and 8.25 inches for 12V4 inch brakes.

NOTE: There must be full thread contact between the clevis and push rod. The push rod must not extend more than 0.12 inch past the clevis and the threaded hole. Cut down the push rod if required.

Do not push level into clevis to align pinholes. Use a 12-mm box wrench and rotate adjusting nut clockwise to move slack adjuster into clevis. 1. Rotate control arm away from adjusting hex nut and toward brake chamber until a definite

Internal stop occurs. The "Installation Indicator" must fall within the slotted area with the brake released.

2. Place anchor stud through the slotted S-cam bracket and install the lock nut. 3. Insert anchor stud into control arm bushing. Tighten lick nut to 40-50 ft-lbs. (54-68 Nm). While

tightening make sure that the control arm does not move out of position and the "Installation Indicator" remains within the slotted area.

4. Check the installation by removing clevis pin and pressing stack adjuster into clevis. When the adjuster is released, the adjuster hole and clevis should remain in alignment.

5. Install the clevis pin retainer and check that the clevis jam nut is tightly locked. 6. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should

be approximately 1.5 Inches. If the stroke is more than 1.5 Inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut clockwise.

CAUTION

Brakes


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Gunite Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound


2. Remove standard clevis and clevis pin from brake chambers and back off jam nut.

3. Secure the slack adjuster on the camshaft by assembling the spacing washers and snap ring.

4. Install chambers on brackets. 5. Remove special clevis from automatic slack

adjuster and install it on the air chamber push rod so that distance from the 0.50-inch clevis hole push rod to the chamber face is 7.62 inches. Tighten the jam nut.

NOTE: There must be full thread contact in the clevis boss. If the push rod threads protrude through the yoke more than 0.06 inch, remove the clevis and cut the push rod to length. 6. The slack adjuster should be in the correct location (7.62 inches from the center line of the clevis

pin hole in the slack adjuster to the air chamber mounting bracket face with the brakes in the OFF position). If it is not, reposition the slack adjuster by turning the adjusting nut manually until distance is 7.62 inches.

7. To align the automatic slack adjuster with the clevis: • Rotate the manual adjuster clockwise until the 0.50 hole in the slack arm is aligns with the

0.50 hole in the clevis. Install the clevis pin and cotter pins. • Align the 0.25 holes in the clevis and link. Install the 0.25 pin and cotter pin.

NOTE: Rotating the manual adjuster clockwise or counterclockwise will aid in aligning the 0.25 hole. 8. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should

be approximately 1.5 Inches. If the stroke is more than 1.5 inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut clockwise.

Brakes


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Bendix Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound


2. Remove standard clevis and clevis pin from brake chambers and back off jam nut to approximately 1.25 Inches from end of push rod.

3. Remove the adapter from the slack adjuster and Install it on the push rod approximately 0.75 inches from the end of the rod. (For snap nut option: Install adapter 1.25 inches from end of rod. Install the retaining ring on the adapter bushing, making certain that it is in the bushing groove.)

4. Secure the slack adjuster on the camshaft by assembling the spacing washer and snap ring.

5. The slack adjuster should be in the correct location from the center line of the clevis pin hole in the slack adjuster to the air chamber mounting bracket face with the brake In the OFF position. If It Is not, reposition the slack adjuster by turning the adjusting nut manually until the correct location is achieved.

6. Install chamber on bracket with push rod in hole in yoke. 7. Turn the external adjusting nut in the direction indicated by the arrow on the crank arm until the

push rod enters the slack adjuster yoke assembly. (For snap nut option: Fully compress the legs of the retaining ring and continue turning the adjusting nut until the adapter is completely in the yoke. Check that the retaining ring is seated in both the yoke and adapter bushing groove by manually pulling on the slack arm in an attempt to separate the adapter bushing ands yoke.)

NOTE: The push rod must not extend 0.12 inch past the surface of the throat of the yoke. If required, cut down the push rod. 8. While holding the yoke in place, screw the adapter into the yoke and tighten the jam nut securely against the adapter. 9. The distance from the center line of the clevis pin to the chamber face should 7.62 inches. Turn the adjusting nut accordingly. NOTE: Torque required to rotate the adjusting nut in the direction opposite to the crank arrow must be as high as 70 ft-lbs. (95 N«m). 10. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should be approximately 1.5 inches. If the stroke is more than 1.5 inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut.

Brakes


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Meritor Automatic Slack Adjuster 1. Apply an even coat of anti- seize compound

(10 and 28 serration splines STK.70033, 37 serration splines - STK70255) to serrated or splined surface of camshaft.

2. Remove standard clevis and clevis pin from brake chambers and back off jam nut.

3. Tighten the jam nut to 40- 50 ft-lbs. (54-68 N»m). The push rod must now be a maximum of 0.17 inch less than flush with the collar or extending no more than 0.25 inch beyond the collar.

4. Secure the slack adjuster on the camshaft by assembling the spacing washers and snap ring.

5. The slack adjuster should be in the correct location (7.67 inches from the center line of the clevis pin hole In the slack adjuster to the air chamber mounting bracket face with the brakes In the OFF position). If it is not, reposition the slack adjuster by turning the adjuster nut manually until the correct location is achieved.

Do not turn the manual adjusting nut clockwise without first removing the pressure relief capscrew. Damage could occur to the pawl spring and adjusting pawl. When replacing the adjusting pawl and capscrew assembly, make sure the indicator is properly seated in its bore. NOTE: If removed, tighten the pressure relief capscrew to 15-20 ft-lbs. (20-27 N*m) when reinstalling. 6. Final brake adjustment is recommended to ensure proper initial brake operation. The slack

adjuster will then seek the proper working strike during vehicle operation.

CAUTION

Brakes


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Camshaft and Camshaft Bearing Removal

1. Remove the brake shoe and slack adjuster

as described in this manual. 2. Remove the snap rings from both ends of

the camshaft. 3. Remove the camshaft by sliding it out of

the axle housing and bearings. It may be necessary to tap the end of the shaft with a soft mallet to release it from the bearings.

Brakes


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4. Remove the two bolts and nuts securing the camshaft bracket to the axle housing.

5. Remove the remaining two bolts from the camshaft bracket and remove the bearing and seals from the bracket.

6. Inspect bearings and seals for wear and deterioration. Replace as necessary.

Brakes


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Camshaft and Camshaft Bearing Installation

Brake Camshaft Rotation: Cam brakes must be installed so the rotation of the camshaft is in the same direction as the brake drum when the vehicle is moving forward. 1. Clean the camshaft assembly. 2. Clean the faces of the anchor bracket and camshaft bracket. 3. Assemble camshaft bearing and seals into the camshaft bracket. Install the two bracket bolts and

nuts and tighten to 20-30 ft-lbs. (27-41 N«m). 4. Attach the camshaft bracket to the axle,

securing it with the remaining bolts and nuts. Tighten the bolts to 35-45 ft-lbs. (47-61 N»m).

5. Install the camshaft bearing assembly and O-rings into the spider.

6. Install the camshaft by sliding it into the bearing in the spider and the camshaft bracket.

7. Install the snap rings at both ends of the camshaft.

8. Install the slack adjuster and brake shoes as described in this manual.

9. Lubricate the camshaft bearings with the specified grease.

Brakes


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Brake Adjustment

1. Adjust the slack adjuster until the brake lining contacts the brake drum. 2. Apply the brakes using normal operating pressure (average line pressure should be 90 psi, but

not less than 80 psi). Check the following while brake pressure is applied. • Distance of push rod level. The maximum push rod travel should be no more than 2 inches as

regulated under FMVSS-121 and/or CMVSS-121. • Angle between push rod and slack adjuster. The angle, with brakes applied, should be 85° to

95°. • Brake lining to drum contact. A 0.010-inch feeler gauge should not fit between the lining and

the drum contact area. 3. Release the air pressure from the brake system and check to see that all brakes release to the

normal relaxed position. NOTE: When automatic slack adjusters are used, always follow the installation and adjustment procedures provided by the automatic slack adjuster manufacturer. Failure to follow he recommended procedure could result in improper operation of the automatic slack adjuster, resulting in reduced brake performance or premature lining wear.

Brakes


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ABS Sensor Replacement NOTE: ABS sensors must match the system. Do not mix sensors from different manufacturers. Removal 1. Manually release the brakes. 2. Remove the drum. 3. Disconnect the ABS sensor connector. 4. Remove the sensor from the sensor holder

by pulling straight out. 5. Remove the sensor retaining spring clip, if

necessary.

ABS Sensor Installation Note: be sure to use the correct spring clip for the sensor being installed. 1. Install the sensor retaining spring clip, if

removed. Into the sensor holder. 2. Install the ABS sensor into the spring dip

and sensor holder. Push the sensor in until it contacts the tooth wheel.

3. Connect the ABS sensor connector. 4. Install the brake drum (if using outboard

drum) 5. Adjust brakes as described in this manual.

Troubleshooting


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Troubleshooting

Troubleshooting Guide Problem Probable Cause Corrective Action

Brake shoes bound up at anchor pins Lubricate brake operating partsBrake hoses restricted Replace hosesBrakes out of adjustment Adjust brakesDamaged brake assembly Replace or repair as requiredSource of air supply shut off at tractor Open cutout cocks at rear of tractor

cab or push control valve "IN"Low brake line pressure Check air pressure gauge on tractor

- inoperative compressorBrake lines between tractor and trailer not properly coupled

Properly couple brake lines

Reservoir drain cook open Close drain cockLeaf spring broken Replace complete springBent axle Replace or straighten axleFrame or suspension out of alignment Straighten frame or align axlesOver or under inflation Inflate to proper pressureLoose wheel stud nuts or clamps Tighten wheel stud nuts or clampsLoose or tight wheel bearing adjustment Adjust bearingsAxle bent or out of alignment Straighten, align or replace axleTires not properly matched Match tiresImpproper acting brakes Correct brakes as requiredRapid stopping Apply brakes slowly when

approaching stopHigh-speed driving on turns Reduce speedOil, grease or foreign material on brake lining

Reline brakes

Brakes out of alignment Adjust brakesBrake drum out-of-round Replace brake drumDamaged brake chamber or internal assembly

Replace or repair as required

Leaky or broken hose between relay valve and brake chamber


Excessive heat cracks on drum

Rapid stopping or poor air flow to brakes Replace drum

Out of adjustment Adjust brakesBinding cam, anchor pins or chamber rod end pin

Lubricate and free up

Damaged brake assembly or brake drum out of round


ABS inoperableLack of lubrication Lubricate brake operating partsExcessive travel in brake chamber push rod

Adjust brakes

Restriction in hose or lines Repair or replaceDefective brake valve Replace brake valve

Grabbing brakes

Refer to ABS manufacturer's service literatureSlow brake application or release

Brake dragging

Brkes will not release

No brakes or insufficient brakes

Dog tracking

Uneven tire wear

Specifications and Maintenance


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Torque Chart

Component Torque ValueGrease 20-50 in-lbs (2-6 Nm)Hex Nut, 3/8-16, Grade 8 35-45 in-lbs (47-61 Nm)Hex Nut, 3/8-16, Grade 5 20-30 in-lbs (27-41 Nm)Adjustment Nut, Bearing 125 in-lbs (169 Nm)Axle Nut, Second 250-300 in-lbs (339-406 Nm)Outer Jam Nut 300-400 in-lbs (406 Nm)Air Chamber Nuts 80-100 in-lbs (108-136 Nm)Dust Shield Bolts 13-17 in-lbs (18-23 Nm)Hubcap 60-70 in-lbs (81-95 Nm)Hubcap Bolts 13-17 in-lbs (18-23 Nm)

Recommended Service and Maintenance Schedules

Component Surface to be Lubricated

Lubricant STK No.

Type of Lubrication

Frequency

Brakes Camshaft (four grease fittings per axle)

STK 013922

Lubriplate No. 630AA

Every 20,000 miles or 4 months

Brakes Brake Shoe Rollers Anchor Pins

STK 013922


100,000 miles or at brake reline

Brakes - Slack Adjuster

Slack Adjuster Grease Fitting

STK 013922


Every 20,000 miles or 4 months

Pro-Par Axle Bearings and Hubs STK 070045

All-Weather Oil SAE 80

100,000 miles or at brake reline

NOTE: Intervals are based on normal operations. Reduce Intervals to compensate for abnormal operations or severe conditions. During Inactive periods, sufficient lubrication must be performed for equipment preservation.



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Recommended Inspection Schedule NOTE: Intervals are based on normal operations. Reduce intervals to compensate for abnormal operations or severe conditions.

First Service • Check torque settings of all wheel nuts - On delivery

- After all wheel changes

After first 5000 km • Check and adjust all wheel bearings.

Every 5,000 km or Once a Month (Whichever Comes First) • Check ABS (if applicable) for proper operation. • Check secondary and parking brake system (if applicable) for proper operation. • Check tires and wheels (torque wheel nuts to proper torque). • Check axle fluid level, add fluid if required. • Check wheel seals for leaks. • Inflate tires to proper pressure. • Inspect brake system gladhands, hoses, tubing, chambers, valves and reservoirs for leaks or

damage. • Check chamber push rod travel and adjust brakes. • Check lining thickness (remove dust shields, if necessary). Do not remove wheels. • Visually check axle alignment.

Every 25,000 km or 4 Months (Whichever Comes First) • Inspect brake drums and wheels. • Inspect brake linkage and shoes. • Inspect brake lines and hoses for chafing, looseness and deterioration. • Test brakes for action, side pull and synchronization. • If equipped with ABS, run complete system check. • Perform soap suds leak test on entire air system. • Drain reservoirs. • Check axle alignment.

Every 100,000 km or 1 Year (Whichever comes first) • Remove the hubcaps and inspect the wheel bearings and lubricant. • Replace the lubricant if it appears badly contaminated. • Re-adjust the wheel bearings and re-torque the axle lock nut. • Replace the hubcaps and ensure the correct amount of lubricant is in the hub end. • Check that the hubcap gasket is not damaged. Replace as necessary. • Check the axle for brake wear; check the rest of the axle components for wear or damage. • Repair, adjust or replace as necessary.

Every 300,000 km or 3 Years (Whichever come first) • Remove was and inspect the wheel bearings, replace as necessary. • When re-assembling the wheel bearings, ensure they are correctly lubricated and adjusted.



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Important Torque Settings

Wheel Nuts Nm ft lbs ISO M22 550-600 400-450 BSF 7/8” 475-540 350-400 DIN M22 515-540 380-400 The wheel nuts must be re-torqued every month or after every wheel change. Nm ft lbs U-Bolts 500-540 370-400 Torque Arm Bolt 290-350 215-260 Pinch Bolt 95 70 Equalizer Bolt 290-350 215-260

Axle Part List


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Axle Part List

Spare Part List

ITEM QTY PART NO DESCRIPTION1 2 804345 Threaded Hub Cap5 2 800110 Axle Spindle Adjusting Nut6 2 800111 Axle Spindle Lock Washer9 2 800064 Outer Bearing Cone10 2 866250 10 Stud Brake Drum, BSF, 16½" X 7"

2 801163 10 Stud Brake Drum, JIS, 16½" X 7"2 866879 8 Stud Brake Drum, JIS, 16½" X 7"

11L 1 800089 10 Stud Hub Assy, BSF, L.H.1 800101 10 Stud Hub Assy, JIS-M, L.H.1 800097 8 Stud Hub Assy, JIS-M, L.H.

11R 1 800090 10 Stud Hub Assy, BSF, R.H.1 800102 10 Stud Hub Assy, JIS-M, R.H.1 800098 8 Stud Hub Assy, JIS-M, R.H.

12 4 800017 Cam Roller13 4 800018 Cam Roller Retainer14 2 800016 Shoe Return Spring15 4 800002 Anchor Pin Bush16 4 800015 Brake Retainer Spring17 4 800167 Brake Shoe Lined18 4 800013 Spring Retainer Pin19 4 800014 Anchor Pin20 2 800003 Dust Shield

Axle Part List


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ITEM QTY PART NO DESCRIPTION21 12 800067 Self Tapping Screw22 12 800069 Lock Washer23 1 801820 Axle Beam Assy, 1820mm Square Track

1 802417 Axle Beam Assy, 1820mm Round Track24L 10 800021 Stud, BSF, L.H., included with item 11

8 800025 Stud, JIS-M, L.H., included with item 1124R 10 800022 Stud, BSF, R.H., included with item 11

8 800026 Stud, JIS-M, R.H., included with item 1125 2 800065 Inner Bearing Cap, included with item 1126 2 800065 Outer Bearing Cap, included with item 1127 2 800723 Seal Assy - Grease, included with item 1128 2 800052 Slack Adjuster, 6" X 37" Spline29 2 800001 Cam Support Bushing30 8 800068 Self Tapping Bolt31 2 800005 Cam Shaft Bushing32 4 800032 Cam Shaft Seal33 2 800033 Spacer Washer, 1½" Dia.34 4 800034 Snap Ring, 1½" Dia.

35L 1 09690L Cam Shaft, 37-Spline, L.H.35R 1 09690R Cam Shaft, 37-Spline, R.H.36 2 800064 Inner Bearing Cone37 2 800104 Spacer Washer, 1¼" Dia.38 2 800102 Snap Ring, 1¼" Dia.

39L 10 800051 Capnut-outer, BSF, L.H., Optional39R 10 800052 Capnut-outer, BSF, R.H., Optional40 10 800053 Centering Washer, BSF, Optional41 2 802400 Brake Chamber Type 24, Optional42 2 803000 Brake Chamber Type 30, Optional43 2 803030 Brake Chamber Type 30/30, Optional

Applicable Axle Model:

• PFRD-245-167-10B • PFRD-245-167-10J • PFRD-245-167-8J


SECTION II - TMC Fifthwheel

Coupler Service Manual

Fifthwheel Operations


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Instructions 1. Disconnect security check-dip 'G' (if fitted).

Before coupling, the TMC Fifthwheel Coupler is pre-set by lifting up and pulling out operating handle 'F'. Secure handle notch 'A' on coupler plate or in cocked position shown in Fig. 1.

2. Before coupling, adjust height of semi-trailer

to match tractor Fifthwheel. Apply trailer handbrake and coupler tractor to semi-trailer. The Kingpin automatically trips and locks the TMC Fifthwheel coupler mechanism. Visually check (a) the trailer seats fully on the TMC Fifthwheel coupler (b) the Kingpin has engaged the TMC Fifthwheel coupler (c) operating handle notch 'F' has located inside the TMC Fifthwheel coupler plate. Refit check-clip 'G' (if fitted) to secure handle to TMC Fifthwheel coupler plate. A spring loaded plunger acting under the handle prevents its movement in transit.

3. To uncouple. Wind semi-trailer landing legs to

the ground, apply trailer handbrake and disconnect tractor/trailer brake lines. Disconnect check-clip 'G' (if fitted), lift up and pull out operating handle and secure by notch 'A' on coupler plate. Driving away the tractor resets the TMC Fifthwheel coupler ready to re-couple automatically as Fig. 1



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Fifthwheel Maintenance • Clean and lubricate top surface. Use grease.

Weekly and New Couplings • Clean and examine top surface. Dress score marks and burrs. Discard excessively worn or

scored couplers. Lubricate top plate. • Checks hook 'B' and wedge 'C' for

wear. Fit dummy Kingpin or couple to trailer, slacken locknut 'P' and withdraw adjusting screw 'R'. Lubricate thread then turn screw until resistance of plunger is felt. Back off the screw by half-a-turn and then lock the nut 'P'. If handle is 'Jammed' in dosed position when uncoupling, the grip on Kingpin is too tight - re-adjust. If correct adjustment cannot be obtained, fit new hook 'B' and wedge 'C'.

• Apply grease to grease valve 'H', handle locking plunger 'S' and lever pivot 'E'. • Check mounting feet M24 set screws 'J' are tight to 35 kg.m. (250 lbs.ft.) • Check mounting feet bolts (12 off) are tight to torque 25 kg.m. (180 lbs.ft.) • Check rubber mounting feet bushes 'K' for wear by rocking coupler fore and aft. A stiff

resistance should be felt with coupler returning to original position when hand pressure is released. Change bushes if necessary, fit new lock washers and tighten M24 set screws 'J' to 35 kg.m. (250 lbs.ft.)

Note: Rubber strips peeling from the bush ends can occur due to rubber expansion during tightening and is acceptable providing the prior paragraph 6. Checks are satisfactory. • Check hook and plunger pivot bolts 'M' and 'N' are secure and that welds are intact. • Check hook spring '0' and main spring 'D' are not stretched or damaged. • Examine security check clip 'G' for damage (if fitted) and renew if necessary.

Every 5000km or monthly (Whichever Comes First) • It is recommended that the coupler is

removed from the tractor for a more detailed inspection of the reinforcing framework and mounting feet for cracks and weld failure.

Troubleshooting


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Troubleshooting

Troubleshooting Guide

Problem Probable Cause Corrective ActionKing Pin position too high Skid plate should be approximately 50mm lower

than the Fifthwheel plate.Skid plate not flat, king pin wrongly positioned

Replace skid plate, permissible flatness tolerance 2mm.

Damaged hook (T2888) Replace the damaged hookInsufficient lubrication Open mechanism and greaseDamaged hook spring (T2881) Replace the damaged hook spring

Outfit is not on level ground or is applying pull to Fifthwheel

Repark outfit

Insufficient lubrication, damaged hook or damaged plunger, resp. incorrect adjustment of locking mechanism

To open jammed Fifthwheel push handle forward and pull out. A second person should stand on the opposite side of the Fifthwheel and strike he boss on release level Operating Lever (T2866) in region of the Handle Pin (T2873), so that the locking bar is loosened. Afterwards any damaged parts must be replace and locking mechanism readjusted.

Damaged hook (T2888) Replace the damaged hook

Damaged hook spring (T2881) Replace the damaged hook spring

Excessive play in the mounting feet bearings

IN case of wear replace the bearings (using bearing kit TK2801)

Excessive play in the locking mechanism

Examine king pin and replace if necessary. If there is still wear although the king pin is new, adjust locking mechanism. If the wear remains, replace the hook and horseshoe ring.

Fifthwheel will not lock-up

Fifthwheel will not unlock

Fifthwheel mechanism will not stay in the preset Movement between Fifthwheel and Trailer

Fifthwheel Part List


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Fifthwheel Part List

Spare Part List

ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION1 T2875 Handle Assy 16 T2878 Collar2 T2886 Washer 17 T2879 Set Screw3 T2874 Handle Pin 18 T2869 Spring-Handle4 T2873 Split Pin 19 T2868 Sleeeve-Handle5 T2877 Nut Castle 20 T2867 Bush6 T2872 Connector-Handle 21 T2876 Bearing Bolt7 T2882 Main Spring 22 T2880 Adjuster Rod Assy8 T2885 Split Pin 23 T2888 Hook9 T2883 Bolt-Plunger 24 T2866 Operating Lever10 T2889 Horseshoe Ring 25 T2884 Plunger11 T2887 Hook Pin 26 T2865 Nut Castle12 T2871 Grease Nipple 27 T2864 Latch Lever13 T2881 Hook Spring 28 T2863 Collar14 T2870 Foot-173mm Height 29 T2862 Spring-Handle15 T2890 Set Screw 30 T2861 Bolt

TK2801 Bearing KitTK2800 Coupling Kit


SECTION III - TMC Landing Gear Service

Manual

Landing Gear Operations


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Landing Gear Operations

Installation

• Semi-trailer landing gear is an important safety component when the prime mover is removed. Furthermore, such gear is subject to high loads while coupling or uncoupling is going on. For that reason, careful installation is required.

• Prior to installing the landing gear, both legs must be fully retracted thus utilizing full lift after the connecting shaft has been installed and ensuring simultaneous ground contact and uniformly distributed load on both supports.

• The legs have to be perpendicular and aligned relative to each other to prevent any impeded motion of the connecting shaft through stress.

• To relieve the screws it is recommended to provide stops above the screw-on plates. • A most important aspect is to provide a sufficient propping of the legs in longitudinal as well

as lateral direction as shown in Figure 1. The angle between the longitudinal and lateral struts and the leg should be at least 45° and appropriately dimensioned to withstand a shearing force of 3 tons.

Operational Instructions Extending the landing gear

• To operate the landing gear, take crank handle from bracket and engage on shaft. • Change into high gear by drawing out crank shaft using crank handle. • Extend landing gear to touch the ground. • Change to low gear by pushing in crankshaft using crank handle. • Raise semi-trailer body to desired height.

Retracting the landing gear • To connect trailer to prime mover, operate landing gear in reverse order.

Maintenance The gear boxes of the landing gears are already filled with grease at delivery and should therefore only be lubricated if handle becomes difficult to turn, using the grease nipples provided.

Prior to painting, cover up or retract inner tube.

WARNING

Landing Gear Part List


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Landing Gear Part List

Spare Part List

ITEM QTY PART NO. DESCRIPTION1 1 LG285001 Upper Housing LH2 1 LG285002 Upper Housing RH3 2 LG285003 Retracting Tube Assy

C/W Grease Tube4 1 LG200001 Universal Crank5 1 LG200002 Crank hanger6 2 LG200003 Strut bracket7 11 LG240001 Screw, Cover and

Gearbox8 2 LG200004 Cover9 2 LG220001 Pinion Gear10 3 LG220002 Woodruff Key11 2 LG240002 Thrust Washer12 2 LG240003 Thrust Washer LH13 2 LG240004 Groove Pin14 2 LG220003 Bevel Gear15 2 LG240005 Washer16 3 LG240006 Grease Fitting17 2 LG200016 Shift Shaft Support18 2 LG220004 Thrust Bearing19 2 LG200005 Collar20 2 LG220005 Cover Gasket21 1 LG200006 Jack Shaft LH22 4 LG240007 Roll Pin23 3 LG240008 Bolt Crank and Cross

Drive24 2 LG240009 Hex-Heavy Duty Bolt25 5 LG240010 Self-Locking Nut26 6 LG240011 Flat Washer27 1 LG200007 Gearbox Half-Outside28 1 LG200008 Gearbox Half-Inside29 1 LG220006 Gasket30 1 LG220007 Input Gear31 1 LG220008 Output Gear32 1 LG200009 Jack Shaft RH33 1 LG200010 Spacer Bushing34 1 LG220009 Idler Gear35 1 LG240012 Groove Pin36 1 LG200011 Shift Shaft37 1 LG240013 Shift Lock Spring38 1 LG240014 Shift Lock Ball39 2 LG200012 Bushing40 1 LG200013 Shoe Boss41 2 LG200014 Shoe Axle42 2 LG200015 Shoe


SECTION IV - TMC CS

Mechanical Suspension

Service Manual

Installation


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Installation

Installation of Suspension Hangers Position the two front suspension hangers onto the trailer frame. Ensure that they are square to the frame and located in line longitudinally and transversely. All dimensions longitudinal, transverse and diagonal are to be within 2mm maximum variation. Position all the other suspension hangers onto the trailer frame, ensuring all the dimensions are held to within 2mm maximum variation. A suspension dimensional layout drawing is supplied with each suspension kit; extra copies of the dimensional drawing can be obtained by contacting our nearest TMC branches. Tack welds all the suspension hangers in position; recheck the positioning of all the suspension hangers to comply with the 2mm maximum variation before final welding of the suspension hangers. All welding between the suspension hangers and the trailer frame is to be done using either low hydrogen electrodes or an approved equivalent MIG process.

Weld all around the top of each suspension hanger in 10mm continuous fillet weld.

After installation of all the suspension hangers, it is recommended that between all pairs of front hangers and equalisers hangers either a pipe or channel type cross bracing is fitted. Fully weld around the ends of the cross bracing to each suspension hanger.

Installation of Axle Seats, (Spring Seats) Position the axle seats on the axle tube at the correct spring centres, the spring centres and suspension hanger centres must be the same dimension. The axle seats must be located equally either side of the axle centre. The axle seats are to be located on top of the axle for overslung suspensions and under the axle for underslung suspensions. For cambered axle installations, care must be taken to ensure the correct positioning of the axle seats relative to the top centre mark of the axle. The axle seats must be aligned flat and parallel to each other. Tacks weld each axle seat in position and recheck the positioning of the axle seats before final welding. Weld the axle seats to the axle tube using either low hydrogen electrodes or an approved equivalent MIG process. Weld each axle seat in position using 8mm continuous fillet weld as per the welding diagram below.

Installation


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Assembly of Torque Arms Assemble the adjustable torque arms to the same length as the matching fixed length torque arms. It is recommended that the fixed length torque arms are fitted on the near side (kerb) of the trailer and the adjustable torque arms are fitted on the off side of the trailer. Fit the end of the torque arm into the suspension hanger or axle seat casting; insert the tapered rubber (or poly) torque arm bushes in from either side. Fit the torque arm pin through the rubber bushes (or poly); fit the torque arm washer and lock nut onto the end of the torque arm pin. Check that the torque arms are located centrally in the end of the hanger or axle seat and tighten the torque arm pin nut. Assembly Torque Torque arm pins: 1" UNF nut 180/220 Nm. (Rubber bush) 1" UNF nut 250/300 Nm. (Poly bush) Assembly Notes: 1. On two and three axle suspensions, the middle and rear torque arms are longer than the torque

arm fitted to the front axle. 2. On all underslung suspensions, the adjustable torque arms are to be fitted with the clamp bolts to

the top as shown on the assembly drawings. 3. On installation, lubricate the rubber torque arm bushes with a soapy solution; do not use liquid

detergent or rubber grease. 4. On installation, lubricate the poly torque arm bushes with rubber grease only.

Final Assembly Fit the springs to the axles ensuring that the hook ends of the springs are to the rear of the axle as installed into the suspension. Assembly Torque U bolts: 7/8" UNF nut 500/540 Nm 1" UNF nut 750/800 Nm After fitting the springs to the axles using the U bolts provided, position the torque arms into the hanger assemblies, ensuring the springs fit up into the hangers and equalisers and locating spring drop out bolts. Tighten the torque arm pins and drop out bolts.

Installation


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Axle Alignment and Adjustment Procedure Measure from the centre of the kingpin to a centre point on each end of the front trailer axle; adjust as needed the adjustable torque arm's length to get the two dimensions equal. Then align the remaining axles off the front trailer axle by adjusting the length of the adjustable torque arm(s) until the axle centres on both sides of the trailer are equal. It is possible also to do the axle alignment using a laser or optical aligning device designed for axle alignment. After the axle alignment is completed and re checked, tighten the adjustable torque arm clamp bolts. Assembly Torque Torque arm clamp bolts: 1/2"UNF nut 90/100 Nm

Service


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Service

Recommended Service Schedule

First Service 500 km or on Delivery • Check all torque settings and re torque.

Every 10,000km or every 2 Months (Whichever Comes First) • Check all torque settings and inspect for visual damage and wear. • Repair and replace parts as necessary.

Every 50,000 km or Annually (Whichever Comes First) • Check all torque settings and inspect for visual damage and wear. • Check all suspension bushings for wear and deterioration replace or repair as necessary. • Check all leaf springs and U bolts for wear and deterioration, replace or repair as necessary. • Carry out a visual inspection of the suspension for wear and damage, repair or replace any

worn or damaged parts as necessary. • Check the axle alignment and realign as necessary. Axle alignment must be checked

whenever severe kerb contact, or accidental damage occurs or the torque arm bushes are replaced.

Note; These are the minimum recommended service requirements for the suspension, dependant on service conditions more frequent service and maintenance schedules may be required for correct operation of the suspension equipment.

Service


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Equaliser and Equaliser Bushes - Assembly Fit the equaliser casting into the suspension hanger casting, insert the tapered rubber (or poly) equaliser bushes in from either side. Fit the equaliser shaft through the rubber bushes (or poly); fit the equaliser shaft washer and lock nut onto the end of the equaliser shaft. Check that the equaliser casting is locate centrally in the hanger casting and tighten the equaliser shaft nut. Assembly Torque Equaliser shaft: 1" UNF nut 290/350 Nm. (Rubber bush). 1" UNF nut 400/450 Nm. (Poly bush). After or during when service work or repairs are being been done on the suspension or any of its components, a visual inspection of the suspension should be carried out to ensure that all component are correctly located and fitted. The incorrect fitment and installation of any components will greatly reduce the service life of the suspension and its components.

General Welding and Repair Notes All welding between the suspension hangers and the trailer frame is to be done using either low hydrogen electrodes or an approved equivalent MIG process. If a suspension hanger must be replaced during repair or service work, weld as follows. Weld all around the top of each suspension hanger in 10mm continuous fillet weld. After installation of the suspension hanger, it is recommended that both the pipe and channel type cross bracing, which was fitted, is replaced and re welded to the new hanger. Fully weld around the ends of the cross bracing to each suspension hanger. When replacing axle seats be sure to re weld the axle seat as follows. Weld each axle seat in position using 8mm continuous fillet weld. Do not weld circumferentially around the axle. If in doubt, consult the TMC Installation Procedure.



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Torque Settings Chart U Bolts: - 500/540 Nm. (7/8" UNF) - 750/800 Nm. (I" UNF) Equaliser Shaft Locknut: - 290/350 Nm. (I" UNF) with rubber bushes. - 400/450 Nm. (I" UNF) with poly bushes. Torque Arm Pin Locknut: - 180/200 Nm. (I" UNF) with rubber bushes. - 250/300 Nm. (I" UNF) with poly bushes. Adjustable Torque Arm Eye Bolts: - 90/100 Nm. (1/2" UNF) Equaliser Drop Out Bolts: - 75/85 Nm. (1/2" UNF)

CS Mechanical Suspension Part List


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CS Mechanical Suspension Part List

Spare Part List

ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION1 202061 Front Hanger 202065/380 Radius Rod - Adjustable 380mm2 202063 Rear Hanger 202065/390 Radius Rod - Adjustable 390mm3 202062 Rocker Hanger 202065/464 Radius Rod - Adjustable 464mm

202041 Rocker Bracket Std 1360mm 202066/380 Radius Rod - Fixed 380mm202042 Rocker Bracket Semi-w ide 1528mm 202066/390 Radius Rod - Fixed 390mm

5 202043 Rocker Shaft 202066/464 Radius Rod - Fixed 464mm6 202043N Rocker Nut 15 202065/547 Radius Rod - Adjustable 547mm7 202044 Rocker Washer 16 202066/547 Radius Rod - Fixed 547mm8 202045 Rocker Bush - Rubber 17 202071 Bolt - Radius Rod

202045P Rocker Bush - Poly 18 202073N Nut - Radius Rod202050 Spring Seat - Ultra Low 127mm 19 202072 Washer - Radius Rod202051 Spring Seat - Low 127mm 20 202073 Bush - Radius Rod202055 Spring Seat - Low 127mm Bogie 200972/01 U-Bolt - Round

202057 Spring Seat - Low 152mm Square 200975/01 U-Bolt - Square

202052 Spring Seat - Medium 127mm 200972/02 U-Bolt - Round202058 Spring Seat - Medium 152mm Square 200975/02 U-Bolt - Square

202053 Spring Seat - High 127mm 200972/03 U-Bolt - Round202056 Spring Seat - High 127mm Bogie 200975/03 U-Bolt - Square

202059 Spring Seat - High 152mm Square 200972/04 U-Bolt - Round200958 Spring - 8 Leaf 75 X 14 200975/04 U-Bolt - Square

200958/S Spring - 8 Leaf 75 X 14 Short 25 2000912N U-Bolt Nut200958/16 Spring - 8 Leaf 75 X 16 505050 Spring Clamp Plate - Round200959 Spring - 9 Leaf 75 X 14 505052 Spring Clamp Plate - Square200959/16 Spring - 9 Leaf 75 X 16 27 505039 12mm Bolt X 130mm200960 Spring - 10 Leaf 75 X 14 28 505039N 12mm Self Locking Nut200960/16 Spring - 10 Leaf 75 X 16323106 Spring - 8 Leaf 75 X 13

9

11

1224

26

13

14

10

23

22

4

21


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SECTION V - TMC 11T Air

Suspension Service Manual

Installation


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Installation

TMC 11T Air Suspension Installation Instructions The TMC 11T air suspension can be installed using normal workshop equipment, no specialised tools or equipment are required for the air suspension's installation. The air suspension is supplied normally as an assembly with the suspension hangers fitted to the trailing leaf springs, the suspension pivot bushes installed, the trailing leaf spring axle seats fully welded to the trailer axle and with the trailing leaf springs and U bolts installed onto the axle. Although the U bolts will be tensioned during assembly it is recommended that they be re tensioned before final delivery as per the torque settings chart. The order of assembly of the air suspension onto the trailer frame is not critical, but positioning the various suspension hangers and other air suspension brackets correctly is very important. A general arrangement layout drawing is supplied with every air suspension kit; additional copies are available on request from nearest TMC branches.

Recommended Installation Procedure Position two of the suspension hangers onto the trailer frame. It is important to check with the air suspension's general arrangement drawing for the suspension's correct dimensional layout to ensure that the trailer axle's required location in the trailer is correct. Ensure that the hangers are fitted square to the frame and located in line longitudinally and transversely. All dimensions longitudinal, transverse and diagonal are to be within 2mm maximum variation. Then position the other suspension hangers onto the trailer frame (in the case of tandem and tri-axle suspension installations), ensuring that all the dimensions are held to within the 2mm maximum variation. Tack weld all the suspension hangers and brackets in position. It is important to re check the positioning of all the suspension hangers and brackets to comply with the suspension's general arrangement drawing's dimensions for the suspension and that they are held to within the 2mm maximum variation before final welding of any of the suspension hangers. All welding between the suspension hangers and the trailer frame is to be done using either low hydrogen electrodes or an approved equivalent MIG process. Fully weld all around the top of each suspension hanger in a 6mm continuous fillet weld. After installation of all the air suspension hangers it is recommended that all the hangers are fitted with either a channel; angle or flat plate type of cross bracing between the suspension hanger and a chassis cross-member. Fully weld around the ends of the cross bracing onto the suspension hanger and onto the trailer's cross-member. The air bag pedestals should also be supported by either a full cross-member brace or angled plate gussets back onto the trailer frame.

Installation


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Typical Suspension Hanger Brace Arrangement

Mounting of Airbag Pedestal to Frame

Final Assembly The suspension's airbags are to be bolted onto the ends of the air suspension's trailing leaf springs and onto the air suspension's top airbag pedestals. The airbag base plate has to be fitted first to the trailing leaf spring. It is secured to the spring end first using the countersunk M 12x80 bolts and nyloc nuts, the airbag is then bolted onto the end of the trailing spring using the MI 2x80 cap screws and MI 2x40 hex bolts. The top of the airbag can then be attached to the top pedestal bracket using the M12 nyloc nuts. Ensure all the bolts and fasteners are correctly tightened as per the recommended torque settings chart.

Installation


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Assembly of Airbag to Air Suspension Spring

If the orientation of the top and bottom bolts/fasteners on the airbag does not align with the bolt holes in the trailing leaf spring and top airbag pedestal, then the orientation can be changed by using the following procedure:- In the base of the airbag loosen the lock nut, it may be necessary to break the seal between the rubber bellows and the airbag piston so that the airbag's base can be rotated to achieve alignment between the top and bottom airbag attachment bolt holes. Once the two sets of bolt holes are correctly aligned retighten the lock nut in the airbag's piston. The airbag can then be installed into the air suspension. Suspension catch straps must be installed generally as shown on the general arrangement drawing for the air suspension kit supplied, the catch strap and mounting bolts are supplied with the suspension kit, a suitable chassis bracket is to be installed in the trailer's frame to support the catch straps. Care must be taken to position the top catch strap mounting bolt in the correct position, and that the catch straps will not interfere with the operation of the air suspension or trailer axle in service.

Axle Alignment and Adjustment Procedure The alignment is measure from the centre of the kingpin to a centre point on each end of the front trailer axle. Adjust the alignment as needed by rotating the collars on the front hanger on the air suspension's front pivot bolt to achieve the correct alignment. The front pivot bolts must be loosened off so that the front pivot bolt can move backwards or forwards in the front suspension hanger when the alignment collars are rotated. It is recommended that the alignment collars are rotated equally on each side of the suspension forwards or backwards to achieve the correct axle alignment.

Installation


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Then align the remaining axles off the front trailer axle by rotating the alignment collars as described above on each axle until the axle centres on both sides of the trailer are equal. It is also possible to do the axle alignment using a laser or optical aligning device designed for axle alignment if available. After the axle alignment is completed, tighten the front pivot bolt (M30) and then tighten the front hanger wear plate retaining bolts (M12) according to the torque settings chart.

Loosen the M30 suspension pivot bush before attempting to align the suspension. Retighten all bolts after alignment is completed.

CAUTION

Installation


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Levelling Valve Installation The suspension's levelling valve should be installed in the trailer frame in a protected position. Care must be taken to ensure that the levelling valves linkage can move from the air suspension's maximum up position to the air suspension maximum down position without any interference from other frame parts or other suspension and brake components. The levelling valve should be mounted on an adequate chassis bracket and the linkage attached to a bracket mounted centrally on the trailer axles’ beam. The levelling valve should be fitted to the centre axle on tri-axle installations and to the rear axle on tandem axle installations.

Service


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Service

Recommended Service Schedule

On Delivery or at 500 km: • Check all torque settings for all fasteners.

Every 25,000km or Quarterly: • Check all torque settings for all fasteners and inspect for visual damage and wear. • Repair and replace parts as necessary.

Every 100,000 km or Annually: • Check all torque settings for all fasteners and inspect for visual damage and wear. • Check all suspension bushings for wear and deterioration; replace or repair as necessary. • Check all leaf springs and U bolts for wear and deterioration, replace or repair as necessary. • Carry out a visual inspection of the suspension for wear and damage, repair or replace any

worn or damaged parts as necessary. • Check the axle alignment and readjust as necessary. Axle alignment must be checked

whenever severe kerb contact, accidental damage occurs or the trailing leaf spring pivot bush is replaced.

Note: These are the minimum recommended service requirements, dependant on service conditions more frequent service and maintenance schedules may be required for the correct operation of the trailer axle.

Service


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Replacement of Suspension Airbags The trailer can be driven at reduced speeds (maximum of 40kph) with no air in the airbags. Blocking off of the air supply to a damaged / punctured airbag is possible so that the remaining airbags can be used normally (either by crimping the supply air line or blocking off the air port to the airbag) to travel to a service area where the airbag replacement can be effected. Note this is a temporary measure only and airbag replacement must be done effected as soon as practicable.

• To replace an airbag the trailer should be parked preferably on a level hard surface with the brakes applied. The trailer must be set at the correct ride height. Suspension airbags cannot be replaced with the air suspension deflated and sitting on its bump stops.

• With the trailer at or near its correct ride height, place either jacks or stands under the trailer's frame to support it. Either block off the air supply to the airbag to be replaced or deflate the whole air suspension. Remove the air supply line to the airbag, and then the airbag can be unbolted from its position in the trailer's air suspension.

• Replacement airbags as approved by the manufacturer must only be used. Bolt the replacement airbag back into its correct position in the trailer, and reconnect the air supply line to the airbag. Torque all the mounting bolts to the correct values as shown on the torque settings chart. Ensure when fitting the airbag that the rubber bellows are not twisted, the top airbag plate and airbag base can be rotated if alignment is not correct.

• Reconnect the air supply to the air suspension and remove the jacks / stands from under the trailer frame, check the air suspension for air leaks and correct as necessary. Recheck the air suspension's ride height and reset as necessary.

Shock absorber replacement The suspension's shock absorbers only need replacement when they become ineffective or leak oil. The shock absorbers can be replaced by removing both the top and bottom mounting bolts and removing the shock absorber from the air suspension. When replacing the shock absorber, torque the top and bottom shock absorber mounting bolts to the correct values as per the torque settings chart.

Service


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Levelling Valve Adjustment The air suspension's levelling valve should be installed in the trailer frame in a protected position. Care must be taken to ensure that the levelling valves linkage can move from the air suspension's maximum up position to the air suspension's maximum down position without any interference from any frame parts, any suspension parts or any brake components. The levelling valve linkage must be adjusted to keep the air suspension at its correct ride height. Once the correct ride height for the air suspension is determined, this height will be known from the air suspension's model number or as marked on the air suspension's nameplate, the ride height can be set. The ride height is the dimension as shown on the diagram below.

• The trailer should be parked on level ground preferably with the trailer loaded or at least partly loaded and with the trailer brakes released.

• All air reservoirs should be fully charged before any suspension adjustments are performed. After final adjustments have been made, recheck all suspension ride heights with the air reservoirs all fully charged.

• To adjust the air suspension ride height loosen the clamps on the vertical linkage rod and slide the rod through the clamp to achieve the correct suspension ride height. Retighten the clamps.



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Recommended Torque Settings 1. Pivot bolt: - 1100 Nm (M30) 2. Axle U bolts: - 820 Nm (M24) 3. Top Shock Absorber bolt: - 300 Nm (M24) 4. Lower Shock Absorber bolt: - 300 Nm (M24) 5. Top Airbag stud nyloc nut: - 35 Nm (M12) 6. Bottom Airbag bolts: - 35 Nm (M12) 7. Front hanger wear plate bolts: - 70 Nm (M12)

11T Series Air Suspension Part List


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11T Series Air Suspension Part List

Spare Part List

ITEM QTY PART NO. DESCRIPTION1 1 ARS 11-181811 2 Leaf Spring LH2 1 ARS 11-181812 2 Leaf Spring RH3 2 ARS 11-181813 Air Spring4 2 ARS 11-18184 Spring Seat5 4 200971 U-Bolts6 2 606060 Tracking Plate7 2 616161 Spring Clamp Plate8 2 ARS 11-282811 Shock Absorber9 2 212170 Pivot Bolt10 2 211988 Top Bolt Shocker11 2 211989 Lower Bolt Shocker12 2 ARS 11-181824 Pivot Bush13 4 200973 Capscrew14 8 211922 Self Locknut15 8 211933 Self Locknut16 2 211944 Self Locknut17 2 211955 Self Locknut18 4 200933 Washer H.D.19 8 200922 Washer H.D.20 8 200911 Single Coil Lockwasher21 4 200974 Setscrew22 2 - Plain Washer23 2 - Air Chamber Bracket24 2 - Serial Number Plate25 2 ARS 11-181844 Reinforcement Plate26 2 606061 Upper Shim27 2 606062 Lower Shim28 4 - Bolt29 2 ARS 11-181826 Pivot Bracket 400mm Ride Height30 2 - Pedestal Plate31 2 - Cross Brace

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TMC Axle Manufacturing Sdn. Bhd. No 79 & 81 Jalan 5/10B

Spring Crest Industrial Park 68100 Batu Caves

Kuala Lumpur Malaysia

Ph +6 03 6187 7788 Fax +6 03 6187 6722

Email [email protected]

TMC Australia Pty Ltd 78 Star Crescent,

P.O.Box 5028 Hallam Vic 3803

Australia Ph +61 3 8786 3688 Fax +61 3 8786 3699

Email: [email protected]

Wuhan TMC Axle Corporation Ltd. Hubei Wuhan Economic & Technological

Development Zone Wuhan Export Processing Zone A-1

Wuhan Hubei China

Ph +86 027 8429 1843 Fax +86 027 8429 1519

Email: [email protected]

TMC Transport Equipment Asia Pte. Ltd.

No. 21, Toh Guan Road East Toh Guan Centre #05-28

Singapore 608609

Ph/Fax +65 6316 2685 Email: [email protected]

The Group

Installation and Service Manual - [ · PDF fileTable of Contents Page Description Page SECTION...

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