TMC Axle Installation and Service Manual

Transcription

1 Axle Installation TMC Axle Installation and Service Manual The Group

2 Disclaimer Versioning 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. Version Number: v Version Date: November 04 Page 2 of 31

3 Axle Installation 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) Page 3 of 31

4 Axle Installation 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: WARNING 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-tosurface 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. Page 4 of 31

5 Axle Installation CAUTION 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. Page 5 of 31

6 Hub, Bearings and Seal Hub, Bearings and Seal Hub, Bearings and Seal Removal WARNING 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. Page 6 of 31

7 Hub, Bearings and Seal 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. Page 7 of 31

8 Hub, Bearings and Seal WARNING 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. CAUTION 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 CAUTION 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. Page 8 of 31

9 Hub, Bearings and Seal Wheel Seal Installation The following instructions apply to installing wheel seals (Part No. TMC ) in new TMC axle beam assemblies and servicing TMC complete axle assemblies. CAUTION 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 inservice axle, go to Step Remove all dirt, chips and hanging burrs from wheel or hubcap, making sure they are clean and dry. CAUTION 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 ( ), 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 CAUTION 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. Page 9 of 31

10 Hub, Bearings and Seal Bearing Adjustment (Castellated Single Nut - Parallel Spindle) CAUTION 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) CAUTION 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 ft-lbs ( Nm) Page 10 of 31

11 Hub, Bearings and Seal Filling Hub with Lube CAUTION 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. Page 11 of 31

12 Brakes 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. Page 12 of 31

13 Brakes 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. Page 13 of 31

14 Brakes 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 (STK Lubriplate #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. Page 14 of 31

15 Brakes 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. Page 15 of 31

16 Brakes 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. CAUTION 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 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 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. Page 16 of 31

17 Brakes Gunite Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound (STK.70033) to serrated or splined surface of camshaft. 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 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 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. Page 17 of 31

18 Brakes Bendix Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound (STK.70033) to serrated or splined surface of camshaft. 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 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. Page 18 of 31

19 Brakes 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 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. CAUTION 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 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. Page 19 of 31

20 Brakes 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. Page 20 of 31

21 Brakes 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. Page 21 of 31

22 Brakes 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 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 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. Page 22 of 31

23 Brakes 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 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. Page 23 of 31

24 Brakes 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. Page 24 of 31

25 Troubleshooting Troubleshooting Troubleshooting Guide Problem Probable Cause Corrective Action Brkes will not Brake shoes bound up at anchor pins Lubricate brake operating parts release Brake hoses restricted Replace hoses Brakes out of adjustment Adjust brakes Damaged brake assembly Replace or repair as required No brakes or insufficient brakes Source 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 compressor Brake lines between tractor and trailer not Properly couple brake lines properly coupled Reservoir drain cook open Close drain cock Dog tracking Leaf spring broken Replace complete spring Bent axle Replace or straighten axle Frame or suspension out of alignment Straighten frame or align axles Uneven tire wear Over or under inflation Inflate to proper pressure Loose wheel stud nuts or clamps Tighten wheel stud nuts or clamps Loose or tight wheel bearing adjustment Adjust bearings Axle bent or out of alignment Straighten, align or replace axle Tires not properly matched Match tires Impproper acting brakes Correct brakes as required Rapid stopping Apply brakes slowly when approaching stop High-speed driving on turns Reduce speed Grabbing brakes Oil, grease or foreign material on brake Reline brakes lining Brakes out of alignment Adjust brakes Brake drum out-of-round Replace brake drum Damaged brake chamber or internal assembly Replace or repair as required Leaky or broken hose between relay valve Replace or repair as required and brake chamber Excessive heat Rapid stopping or poor air flow to brakes Replace drum cracks on drum Brake dragging Out of adjustment Adjust brakes Binding cam, anchor pins or chamber rod Lubricate and free up end pin Damaged brake assembly or brake drum out of round Replace or repair as required ABS inoperable Refer to ABS manufacturer's service literature Slow brake Lack of lubrication Lubricate brake operating parts application or Excessive travel in brake chamber push Adjust brakes release rod Restriction in hose or lines Repair or replace Defective brake valve Replace brake valve Page 25 of 31

26 Specifications and Maintenance Specifications and Maintenance Torque Chart Component Torque Value Grease in-lbs (2-6 Nm) Hex Nut, 3/8-16, Grade in-lbs (47-61 Nm) Hex Nut, 3/8-16, Grade in-lbs (27-41 Nm) Adjustment Nut, Bearing 125 in-lbs (169 Nm) Axle Nut, Second in-lbs ( Nm) Outer Jam Nut in-lbs (406 Nm) Air Chamber Nuts in-lbs ( Nm) Dust Shield Bolts in-lbs (18-23 Nm) Hubcap in-lbs (81-95 Nm) Hubcap Bolts in-lbs (18-23 Nm) Recommended Service and Maintenance Schedules Component Surface to be Lubricant Lubricated STK No. Brakes Camshaft (four grease STK fittings per axle) Brakes Brake Shoe Rollers STK Anchor Pins Brakes - Slack Slack Adjuster Grease STK Adjuster Fitting Pro-Par Axle Bearings and Hubs STK Type of Lubrication Lubriplate No. 630AA Lubriplate No. 630AA Lubriplate No. 630AA All-Weather Oil SAE 80 Frequency Every 20,000 miles or 4 months 100,000 miles or at brake reline Every 20,000 miles or 4 months 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. Page 26 of 31

27 Specifications and Maintenance 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. Page 27 of 31

28 Specifications and Maintenance Important Torque Settings Wheel Nuts Nm ft lbs ISO M BSF 7/ DIN M The wheel nuts must be re-torqued every month or after every wheel change. Nm ft lbs U-Bolts Torque Arm Bolt Pinch Bolt Equalizer Bolt Page 28 of 31

29 Axle Part List Axle Part List Spare Part List ITEM QTY PART NO DESCRIPTION Threaded Hub Cap Axle Spindle Adjusting Nut Axle Spindle Lock Washer Outer Bearing Cone Stud Brake Drum, BSF, 16½" X 7" Stud Brake Drum, JIS, 16½" X 7" Stud Brake Drum, JIS, 16½" X 7" 11L Stud Hub Assy, BSF, L.H Stud Hub Assy, JIS-M, L.H Stud Hub Assy, JIS-M, L.H. 11R Stud Hub Assy, BSF, R.H Stud Hub Assy, JIS-M, R.H Stud Hub Assy, JIS-M, R.H Cam Roller Cam Roller Retainer Shoe Return Spring Anchor Pin Bush Brake Retainer Spring Brake Shoe Lined Spring Retainer Pin Anchor Pin Dust Shield Page 29 of 31

30 Axle Part List ITEM QTY PART NO DESCRIPTION Self Tapping Screw Lock Washer Axle Beam Assy, 1820mm Square Track Axle Beam Assy, 1820mm Round Track 24L Stud, BSF, L.H., included with item Stud, JIS-M, L.H., included with item 11 24R Stud, BSF, R.H., included with item Stud, JIS-M, R.H., included with item Inner Bearing Cap, included with item Outer Bearing Cap, included with item Seal Assy - Grease, included with item Slack Adjuster, 6" X 37" Spline Cam Support Bushing Self Tapping Bolt Cam Shaft Bushing Cam Shaft Seal Spacer Washer, 1½" Dia Snap Ring, 1½" Dia. 35L L Cam Shaft, 37-Spline, L.H. 35R R Cam Shaft, 37-Spline, R.H Inner Bearing Cone Spacer Washer, 1¼" Dia Snap Ring, 1¼" Dia. 39L Capnut-outer, BSF, L.H., Optional 39R Capnut-outer, BSF, R.H., Optional Centering Washer, BSF, Optional Brake Chamber Type 24, Optional Brake Chamber Type 30, Optional Brake Chamber Type 30/30, Optional Applicable Axle Model: PFRD B PFRD J PFRD J Page 30 of 31

31 TMC Axle Manufacturing Sdn. Bhd. No 79 & 81 Jalan 5/10B Spring Crest Industrial Park Batu Caves Kuala Lumpur Malaysia Ph Fax TMC Australia Pty Ltd 78 Star Crescent, P.O.Box 5028 Hallam Vic 3803 Australia Ph Fax info@tmcaus.com.au Wuhan TMC Axle Corporation Ltd. Hubei Wuhan Economic & Technological Development Zone Wuhan Export Processing Zone A-1 Wuhan Hubei China Ph Fax tmcwh@china.com TMC Transport Equipment Asia Pte. Ltd. No. 21, Toh Guan Road East Toh Guan Centre #05-28 Singapore Ph/Fax khdtan@singnet.com.sg The Group