INSTALLATION AND MAINTENANCE MANUAL E6100 SERIES SPRING SUSPENSION

Transcription

1 INSTALLATION AND MAINTENANCE MANUAL E6100 SERIES SPRING SUSPENSION

2 E6100 Series Spring Suspension The E6100 series suspension system is a three point system available in undermount or underslung set-ups. Single piece equalizers combined with axle seats of various heights lets you custom build your system to match your mounting height requirements. Axle spreads from 44 [1118mm] to 72 [1829mm] are available. All components are formed and fabricated from high quality steel and robotically welded for guaranteed precision and quality. Standard features include the Eveley "Long-Life" metalastic bushings at all pivot connections and large hanger footprint bases. This light-weight heavy duty suspension system is an excellent choice for continuously loaded equipment and offers high stability, low cost, long life and easy installation. An O.E.M. standard for all applications, available as single, tandem, tri-axle or multi-axle units. Superior Performance for the Industry Safety and durability go a long way with this Industry Standard design to give you the kind of superior performance that you've come to expect. Progressive Manufacturing Procedures Using today's "state of the art" manufacturing technologies in Robotics, Micro-electronics and Computers (CAD/CAM), an Eveley suspension has the quality and accuracy from start to finish. The direction here at Eveley is towards better design and manufacturing methods to ensure increased product life, safety and performance. Variable Axle Spacing Axle spacing of 44 [1118], 49" [1245mm], 54" [1372mm], 60" [1524mm] and 72"[1829mm] are available in single, tandem, or multi-axle configurations. Available in undermount and underslung configurations. Axle seat heights of 1 [25mm], 2" [51mm], 3" [76mm] allow a more customized ride height using the same springs. Components that "Go the Distance" High Strength steel used in all hangers and axle connections contribute to the unmatched durability. All pivot points feature high-tech "Long-Life" bushings. All U-bolts are Grade 8 material, and are reverse mounted and roll threaded to allow easy torquing to 700 ft lbs [949J]. 4/15/ pg. 2

3 UNDERMOUNT SUSPENSION Undermount spring suspensions (axle below spring configuration) use 7/8 U-bolts to connect the axle to the suspension for a positive fit. All U-bolts are grade eight material with rolled threads. With the use of the right U-bolt on your underslung suspension, you will experience less maintenance and a safer axle connection. STANDARD AXLE SPACINGS AVAILABLE 44 (1118mm) 49 (1245mm) 54 (1372mm) 60 (524mm) 72 (1829mm) UNDERSLUNG SUSPENSION Underslung spring suspension (axle on top of spring configuration) use 1 forged top U-bolts to connect the axle to the suspension for a positive fit. All U-bolts are grade eight material with rolled threads. With the use of the right U-bolt on your underslung suspension, you will experience less maintenance and a safer axle connection. STANDARD AXLE SPACINGS AVAILABLE 49 (1245mm) 54 (1372mm) 60 (524mm) 72 (1829mm) 4/15/ pg. 3

4 4 3/8" [111mm] E612A49UM UNDERMOUNT 94.5"[2400mm] 44" [1118mm] 42 3/4" [1086mm] 19 1/4" [489mm] 49 1/2" [1257mm] 18" [457mm] 8 3/4" [222mm] 24 3/4" [629mm] 24 3/4" [629mm] 3.38[86mm] 4/15/ pg. 4

5 Eveley International Corp. E612A54UM UNDERMOUNT 4/15/ pg. 5

6 Eveley International Corp. E612A60UM UNDERMOUNT 4/15/ pg. 6

7 E612A72UM UNDERMOUNT 4/15/ pg. 7

8 E6100 SERIES ORDERING INFORMATION In order to avoid confusion, our suspension kit numbering system is simple and easy to use. It contains all necessary information to identify all aspects of the kit requirements. Example: Therefore: A model designated as E613A60UM 15-1/2 TRA1150, is described as a Triaxle suspension from our 6100 Series of suspensions, that spaces the axles at 60"[1524mm] apart and mounts under the main frame rails (UMundermount) at a ride height of 15 1/2 [394mm], using TRA1150 springs. To determine the capacity and ride height you wish your trailer to operate at, we suggest that you refer to the spring selection charts on page 90. Please note that all of our models of suspensions can use any of the three (3) axle seats, 1"[25mm] to 3" [76mm] high, that we manufacture, thereby ensuring that a full range of ride heights that are common to the industry as well as many special ride heights may be achieved using the same spring. IMPORTANT!!! We do not recommend the use of High Arch springs with our E4400 Series tandem and tri-axle models. If added mounting height is required, we suggest the use of one of three axle seats plus the use of our extended hangers. Before specifying the springs to be used, we suggest that you consult the spring selection chart on page 5 of this publication. This gives you the mounting heights available with each type of spring. 4/15/ pg. 8

9 SPRING AND RIDE HEIGHT CHART SYMETRICAL SPRINGS 4/15/ pg. 9

10 E612A49US UNDERSLUNG 4/15/ pg. 10

11 E612A54US UNDERSLUNG 4/15/ pg. 11

12 E612A60US UNDERSLUNG 4/15/ pg. 12

13 E612A72US UNDERSLUNG 4/15/ pg. 13

14 UNDERSLUNG SPRING AND RIDE HEIGHT CHART INSTALLATION PROCEDURES E6100 INSTALLATION INSTRUCTIONS Major components of the suspensions are factory assembled by Eveley to help reduce your assembly time and also to ensure the correct fitting of all parts. FRAME ASSEMBLY 1. Take your measurements from the center of the King Pin position to the rear hanger and tack weld to the trailer frame. 2. Position the remaining hangers using the dimensions shown in the assembly drawings. 3. When all hangers are tacked to the frame, check for correct measurements and squareness to the frame. 4. For final welding instructions refer to Welding Specifications. AXLE ASSEMBLY 1. Position axle so that the brake cam rotation is the same as wheel rotation. Place axle seats on axle so they are horizontal to the axle and parallel to each other. Center to center width measurements of axle seats and hangers must be identical. 2. Tack weld into position, check for squareness and weld as per Welding Specifications. See Axle seat figure 3 -Page 17 4/15/ pg. 14

15 SUB ASSEMBLY 1. Next attach adjustable torque rods to curbside and rigid torque rods to roadside. Insert torque rod bolts so that washers and lock nuts are to the outside. At this stage do not tighten nuts. 2. Install springs, top plates and U-bolts. Line up springs so that distances between the diagonals and the ends are the same. Tighten U-bolt nuts to 700 Ft.lb [949.1 N/m] of torque and torque rod clamp bolts to 90 Ft.lb. [122.0 N/m] of torque. FINAL ASSEMBLY 1. Fit two sub-assemblies together, making sure the lipped end of each spring is located in the equalizer. (With the exception of wide spread where the rear spring assembly can be reversed if required.) 2. Insert spring rebound bolts in equalizer so that 1/2" nuts are to the outside of the trailer. These bolts should only be tightened enough to keep the bolt snug, but loose enough for the bolt to roll if engaged by the spring lip. On the E44 application, no bolt is fitted into the rear equalizer assembly. However, a spring rebound rod should be welded into the position where the bolt would normally be fitted. 3. Connect torque rods to front and center hangers. Tighten all torque rod bolts to 320 Ft.lb. [433.9 N/m]. 4/15/ pg. 15

16 ALIGNMENT AND ADJUSTMENT 1. Make sure the suspension is not binding at any point and that the trailer is resting level. 2. Commence suspension alignment by measuring from center of King Pin to the end centers of the front axle, when completed, measure from front axle centers to second axle centers and so on, depending on the axle configuration. Make sure suspension is in its neutral position. 3. Tighten torque rod clamp nuts to 90 Ft.lb. [122.0 N/m] of torque. 4. Align rear axle to front axle by measuring from the axle centers on each side and shorten or lengthen the adjustable torque arm screw on the rear axle until the measurements are the same. 5. IMPORTANT - Do not lubricate any parts of the suspension or apply grease to the ends of the springs. TRI-AXLE SPREADS Because of the extended length of these suspensions, the relationship between the fifth wheel coupler height and the mounting height of the suspension is very important. When units are designed around a wide-spread triaxle suspension, the designer, should ensure that when coupled to the tractor, the trailer suspension rides in the neutral position. If the unit rides in a semi-equalized state, overloading of the axles will result. This can be corrected by the addition of a riser block to the appropriate axles. This problem could also be experienced on Wide-Spread tandem suspensions with a spread of more than 72" [1829mm] between axle centers. This can be corrected by the addition of a riser block to the first axle. In some cases, two different spring seat heights can be supplied to counteract this situation. Any questions or problems regarding the performance of these suspensions should be directed to this company. 4/15/ pg. 16

17 AXLE SEAT Remember to maintain a tight fit between the axle seat and the axle tube prior to welding. SUSPENSION INSPECTION It is recommended, that after the first 1,000 miles (1,609 km), operators should check all nuts for tightness and re-torque. Re-torquing is essential to the guarantee and ensures proper operation. All torquing should be periodically checked; at 10,000 miles [16,090 km], 30,000 miles [48,270 km], 50,000 miles [80450 km] etc. THIS INSPECTION IS ESSENTIAL Failure to maintain the specified torque on all nuts and bolts could result in excessive hanger wear, bolt wear, bushing failure, broken springs, tire wear, and the stripping of bolt threads. A periodic check by the operator will eliminate these problems. 4/15/ pg. 17

18 WELDING SPECIFICATIONS Any approved welding rod such as 7018 or the equivalent, can be used. A minimum 5/16 (8mm) fillet weld should be used for attachment of hangers to the frame and braces to the hangers Figure 1: Hangers on I-beam sub-frame (standard). Centers of I-beam and hangers are the same. Figure 2: Hangers on I-beam sub-frame (standard). Centers of I-beam and hangers are offset to each other Reinforcing and bracing are req d 4/15/ pg. 18

19 Eveley International Corp. On standard suspension designs for trailers and semi-trailers, all axle and brake moments as well as the biggest portion of the torsional stabilizing forces and a portion of the spring weight vertical forces pass through the front mounting brackets into the vehicle frame. Therefore, the trailer frame must be strengthend as well as the hangers braced. A vertical reinforcement must be placed between the upper and lower flanges and welded to the web of the trailer frame. An angled brace should be placed between the suspension hanger face and a cross member. As shown below. Placing a brace between left and right hanger faces is not recommended 4/15/ pg. 19

20 AXLE SEAT Brackets which wrap around the axle should touch the axle as shown in view A in figure 3. With this type of fit, loads on the bracket are transferred directly to the axle. If a gap exists between the axle and the bracket as shown in view B in Fig.3, these loads are transferred to the weld. This may overstress and crack the weld. The weld arc should not be started at the end of the bead. Instead, the electrode should be started away from the end of the bead and moved as shown in figure 5. Any craters which remain should be filled during this movement. In both cases, the intention of this guidance is to insure that the stress risers which occur when either start or stopping a weld are located away from the ends of the weld. Figure 4: Axle seat on 5 [127mm] diameter axle. When welding axle seat in position mig welding is preferred. Welding wire should be 7018 or equivalent and should be performed so that welding is done in a flat position. If this is not possible welding should be performed using the stick method 4/15/ pg. 20

21 BUMP OUT BLOCKS It is the practice of some manufacturers to install bump out blocks or dumping blocks above the rear axle or axles of a spring suspension. This is supposed to help the stability of the unit during a dumping operation. In most cases the bump out blocks are installed incorrectly, and actually restricts the movement of the suspension and spring under normal operation. This situation causes accelerated wear of the spring and spring hangers, and ultimately creates an early failure of these parts. If the correct spring assembly is chosen for this combination, together with the recommended suspension assembly, the bump out blocks are not required. The stability of the suspension assembly will withstand the dumping operation. Before installing a suspension for this type of application, the manufacturer should check with the suspension supplier (Eveley International Corp.) to ensure that the correct suspension and spring combination has been chosen. Eveley International will not guarantee the performance of its suspensions, or the serviceability of the parts of the suspension, if bump out blocks are installed as part of the suspension assembly. All statements and compliance with our standard warranty policies will be NULL AND VOID under such conditions. This statement applies to all Eveley International spring suspensions assemblies with the following series numbers. E6400 E6000 E4400 E6100 E6200 This includes undermount, underslung, straddle mount, and flange mount models 4/15/ pg. 21

22 EQUALIZATION OF SPREAD AXLE CONFIGURATION When using multi-axle suspensions with extended axle spacing s, the relationship between the fifth wheel coupler height and the mounting height of the suspension is very important. When designing around spread axle suspensions, the manufacturer should ensure that when coupled to the prime mover, and in a loaded condition, the suspension rides in a neutral position. If the suspension rides in a semi-equalized condition it could produce: a.) Overloading of axles. b.) Increased tire and brake wear. c.) Spring breakage. d.) Suspension damage. If the suspension is running in the semi-equalized condition, or if the trailer is designed to have a natural draft to the rear, i.e. Tankers, a Container Chassis, the suspension can be ordered with different axle seat heights for each axle. This will allow the suspension to run in the neutral condition even if the trailer slopes or drafts to the rear. On existing suspensions, this same condition can be attained with the use of riser blocks. The designer should make every attempt to taper the frame and leave the suspension with identical axle seats. Eveley International cannot be held responsible for a suspension not equalizing properly if different axle seats or riser blocks are used. This same condition can also apply to Air-Ride suspensions as well as spring suspensions. For example, on a 48ft [14.63m] trailer with a tri-axle spread suspension on the rear, if the trailer is built for a 49-1/2" [1257mm] coupler height, but is actually running at 52" [1321mm] coupler height, the suspension will have used all of its articulation travel, in the empty condition. In the loaded condition, it will be locked out under normal travel, and will produce excess loadings on the spring ends and spring pads of the suspension. In the case of an Air-Ride suspension, the air bags would be extended outside of their normal working range, which could lead to differential axle loadings and increased component wear. Also to be considered when setting the coupler height of the trailer, should be the compatibility of the truck and trailer suspensions. If the truck suspension is Air-Ride and the trailer is spring, the trailer suspension will automatically use some of its articulation when loaded; the truck however, would always be at its original height. If compatibility is required for various coupler heights, i.e. 50" [1270mm] - 52" [1321mm], then a mean dimension should be chosen for the trailer coupler height, i.e., 51" [1295mm]. This will allow for equalization on the trailer suspension, without constantly running with negative movement. If you require assistance to calculate suspension heights, or more information on suspension equalization, please contact our Customer Service Department. 4/15/ pg. 22

23 EVELEY INTERNATIONAL CORP. PRODUCT WARRANTY This warranty shall be limited to the original purchaser from the date of sale and covers all new components manufactured by Eveley International Corp. to be free of defects in material and workmanship, for one year (parts and labour) and up to five years (parts only) when installed, assembled, and maintained in accordance with Eveley International Corp. installation and maintenance procedures, under normal use and service. The product installer is responsible for providing correct vehicle components and attachments, and providing the clearance for suspension components, axles, wheels and tires. The installer is also responsible to ensure that products supplied by Eveley International Corp. are operating within their engineering designed capabilities and capacities. The product owner is responsible for pre-operation inspection, periodic inspections, maintenance, and use of the product as specified by Eveley International Corp. This warranty is null and void if the products are subject to improper installation, modification, adjustment, unauthorized repair, damage as a result of abuse, accident, and /or negligence, and incorrect or insufficient maintenance or applications, including but not limited to, overloading product ratings or maximum vehicle weight specifications. This warranty is null and void if parts failure or system problems occur as a result of incorrect trailer or frame design. This is the responsibility of the trailer or equipment manufacturer. The responsibility under this warranty is limited to the replacement or repair of defective parts at no charge and is at the discretion of Eveley International Corp. Products to be considered for warranty are to be returned pre-paid to Eveley International Corp.and will be subject to our inspection, or the field inspection by an authorized representative of Eveley International Corp. before warranty is approved. In no event shall Eveley International Corp. be liable for any expense, loss or damage (direct, Incidental, consequential, or exemplary) including, but not limited to, towing expenses, equipment rental, downtime expenses, cargo damage, incidental expenses, or any other losses arising in connection with the sale, use or inability to use the product resulting from a warranty covered part found to be defective. Any allowance for labour costs associated with the repair or replacement of the subject component must be pre-approved in writing by Eveley International Corp. Component parts included in the Eveley International Corp. product but purchased from outside vendors are guaranteed by Eveley International Corp. to the same extent as the guarantee offered by the outside vendor to Eveley International Corp. Any Warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the expressed warranty terms provided in this warranty coverage. All wearable items are not included in this warranty. This warranty is limited to normal on highway use or written approval applications. This warranty does not cover, off road, mining, or raw wood applications. This warranty coverage is for Canada and the United States only. The use of none-genuine Eveley International Corp. replacement parts will void this warranty coverage. No other warranty is expressed or implied by Eveley International Corp. 4/15/ pg. 23