TAG LIFT AXLE SUSPENSION SERVICE MANUAL- 37 T ` Page 0
CONTENT SI.NO Description Page No. 1 Suspension Specification 2 2 Pre-Installation Notes 2 3 Suspension Parts Description 3 4 Dismantling Procedure 4 5 Installation Procedure 12 6 After Assembly Inspection 21 7 Serviceable Part List 22 8 Maintenance Schedule 23 9 Preventive Maintenance 23 10 Special Tool Requirement for Service 25 11 Basic Troubleshoot 25 12 Do s and Don ts in Lift Axle 26 Page 1
1. SUSPENSION SPECIFICATION DESCRIPTION PARAMETER WHEEL BASE (mm) 6100 LIFT AXLE POSITION FROM RA2 (mm) 1440 FRAME HEIGHT (mm) 1110 LIFT AXLE LOAD (T) 6 RIDE HEIGHT (mm) 345 AIR SPRING STATIC HEIGHT (mm) 321.5 LIFT (mm) 206 REBOUND (mm) 130 TYRE SIZE 10R20 TYRE GROUND CLEARANCE AT LIFTED CONDITION (mm) 148.5 2. PRE-INSTALLATION NOTES: 1. Suspensions are designed to operate within specific parameters. Operating the suspension outside the design parameters may result in improper performance, damaged equipment, and void of warranty. 2. The total operating capacity of a suspension is determined by the component with the lowest load rating. Please consult with the manufacturers of tires and wheels to determine the maximum suspension system capacity. 3. Improperly locating an auxiliary suspension on a vehicle can unload or overload the vehicle s primary suspensions. The installer is responsible to ensure the auxiliary suspension is properly located for correct load distribution. 4. The installer is responsible to ensure that air reservoir volume requirements are met. 5. If vehicle chassis modifications are required, consult with the vehicle manufacturer to ensure that such changes are permitted. 6. Welding or altering suspension components are not permitted except where explicitly stated by JAI. 7. The installer is responsible to ensure that there is sufficient clearance to the auxiliary suspension, tires, air springs, axle (including axle to driveline) and steering components. Page 2
3. SUSPENSION PARTS DESCRIPTION: SELF STEERABLE LIFT AXLE 6T TAG Fig-1 PART LIST S.no Part MTBL Part Number Number DESCRIPTION QTY 1 90018180000 7402EAP00860N LBA - LH 1 2 90018190000 7402EAP00870N LBA - RH 1 3 90018030000 7402EAP00880N HANGER-LH 1 4 90018040000 7402EAP00890N HANGER-RH 1 5 90018220000 7402EAP00820N H-H CROSS CHANNEL ASSY 1 6 90008040000 7402FAP00030N UPPER CONTROL ARM ASSY LH 1 7 90008060000 7402FAP00040N UPPER CONTROL ARM ASSY RH 1 8 90008080000 7402FAP00050N LOWER CONTROL ARM ASSY 2 9 90018120000 7402DAP00170N UPPER ASPG MTG ASSY 2 10 91001000600 7402CAP00010N LOAD SPRING 2 11 91001000200 7402CAP00020N LIFT SPRING 2 12 91002000100 7402GAP00010N STEER DAMPER 2 13 91006002600 7403BAP00030N EXT.MALE-ELBOW M12X1.5- Ø12 2 14 91006001300 7403BAP00040N MALE-ELBOW 1/4" NPT - Ø12 2 15 91005000500 7402EAP00900N WEAR WASHER 16 Page 15
4. DISMANTLING PROCEDURE: While doing Servicing of Lift axle it is safe to depressurize the Air bellows (Load spring and Lift spring). 4.1. STEER DAMPER: Steer Damper can be removed by loosening the M18-1.50 X 120 HHCS (Item #2) and M18-1.50 X 110 HHCS (Item #3).Refer below part list.(as shown in the fig-1.1). Fig-1.1 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY GRADE 1 91002000100 7402GAP00010N STEER DAMPER 2-2 91007002200 7402EAP01040N M18-1.50 X 120 HHCS 2 GRADE-10.9 3 91007000500 7402EAP01050N M18-1.50 X 110 HHCS 2 GRADE-10.9 4 91008002700 7402EAP01060N M18-1.50 HEX NUT 4 CLASS-10 5 91008002000 7402EAP01070N M18 - WASHER FLAT 8-4.2 LOAD SPRING: Before removing / inspecting air spring it is safe to depressurize the Air bellows (Load spring and Lift spring). Remove the Pneumatic fitting MALE-ELBOW 1/4" NPT - Ø12 (item #2) from the combo stud. The main spring can be removed by loosening 3/8" - 16NC 1" LG HHCS (item #3), 1/2" - 13NC NYLON INSERT (item #5) and 3/4" - 16NF NYLON INSERT (item #6). (As show in the fig-1.2 & 1.3) Page 16
Fig-1.2 fig-1.3 PART LIST S.NO PART MBTL PART NUMBER NUMBER DESCRIPTION QTY GRADE 1 91001000600 7402CAP00010N AIR SPRING-CONTITECH 2-2 91006001300 7403BAP00040N MALE-ELBOW 1/4" NPT - Ø12 2-3 91007005400 7402EAP00910N 3/8" - 16NC 1"LG HHCS 4 GRADE-10.9 4 91008003400 7402EAP00920N 3/8" - SPLIT LOCK WASHER 4-5 91008000200 7402EAP00980N 1/2" - 13NC NYLON INSERT 2 CLASS-8 6 91008000500 7402EAP01080N 3/4" - 16NF NYLON INSERT 2 CLASS-8 4.2 LIFT SPRING: Before removing / inspecting air spring it is safe to depressurize the Air bellows (Load spring and Lift spring). Remove the Pneumatic fitting MALE-ELBOW M12X1.5- Ø12 (Item #2) from the combo stud. The Lift spring can be removed by loosening M10-1.5 X 20 HHCS (Item #3) and M20-1.50 NYLON INSERT (Item #5). (As show in the fig-1.4 & 1.5) Fig-1.4 fig-1.5 Page 17
PART LIST S.NO PART MBTL PART NUMBER NUMBER DESCRIPTION QTY GRADE 1 91001000200 7402CAP00020N AIR SPRING-FIRE STONE 2-2 91006002600 7403BAP00030N EXTENDED MALE-ELBOW M12X1.5- Ø12 2-3 91007005300 7402EAP00930N M10-1.5 X 20 HHCS 4 GRADE-10.9 4 91008001100 7402EAP00940N M10 - WASHER INTERNAL TOOTH LOCK 4-5 91008000600 7402EAP01110N M20-1.50 NYLON INSERT 2 CLASS-8 4.4 CONTROL ARM: Control Arms (item #1, #2 and #3) can be removed by loosening M22-1.50 X 190 HHCS bolt (item #5). (As show in the fig-1.6) Fig-1.6 PART LIST S.NO PART MBTL PART NUMBER NUMBER DESCRIPTION QTY GRADE 1 90008040000 7402FAP00030N UPPER CONTROL ARM ASSY LH 1-2 90008060000 7402FAP00040N UPPER CONTROL ARM ASSY RH 1-3 90008080000 7402FAP00050N LOWER CONTROL ARM ASSY 2-4 91005000500 7402EAP00900N WEAR WASHER 16-5 91007000700 7402EAP01130N M22-1.50 X 190 HHCS 8 GRADE-10.9 6 91008003800 7402EAP01140N M22-1.50 NYLON INSERT 8 CLASS-10 7 91008003500 7402EAP01150N M22 - WASHER FLAT 16 - Page 18
4.5 LOWER BEAM ASSY LH & RH: Lower Beam assembly can be removed from axle by loosening the M20-1.5 X 90 HHCS as shown in below fig-1.7 Fig-1.7 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY GRADE 1 90018180000 7402EAP00860N LBA - LH 1-2 90018190000 7402EAP00870N LBA - RH 1-3 91007003100 7402EAP01090N M20-1.5 X 90 HHCS 8 GRADE-10.9 4 91008003900 7402EAP01100N M20-1.5 HEX NUT 8 CLASS-10 5 91008000800 7402EAP01120N M20 - WASHER FLAT 16-4.6 HANGER TO HANGER CROSS CHANNEL: Hanger to Hanger cross channel assembly can be removed from Hanger assembly LH and RH by loosening the M12-1.5 X 35 HFS as shown in below fig-1.8. Page 19 Fig-1.8
PART LIST S.NO PART MBTL PART NUMBER NUMBER DESCRIPTION QTY GRADE 1 90018220000 7402EAP00820N H-H CROSS CHANNEL ASSY 1-2 91007001000 7402EAP00950N M12-1.5 X 35 HFS 10 GRADE-10.9 3 91008000100 7402EAP00970N M12-1.5 HFN 10 CLASS-10 4.7 HANGER ASSEMBLY LH & RH: Hanger assembly LH and RH can be removed from frame assembly by loosening the M14-1.5 X 45 HFS and M12-1.50 X 60 HFS as shown in below fig-1.9 Fig-1.9 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY GRADE 1 90018030000 7402EAP00880N HANGER-LH 1-2 90018040000 7402EAP00890N HANGER-RH 1-3 91007001300 7402EAP00960N M12-1.50 X 60 HFS 8 GRADE-10.9 4 91008000100 7402EAP00970N M12-1.50 HFN 8 CLASS-10 5 91007004100 7402EAP00990N M14-1.5 X 45 HFS 20 GRADE-10.9 6 91008000300 7402EAP01000N M14-1.5 HFN 20 CLASS-10 4.8 UPPER AIR SPRING MTG BRKT ASSY: The Upper Air Spring Mtg Brkt assembly can be removed from frame assembly by loosening the M16-1.5 X 50 HFS and M16-1.50 X 55 HFS as shown in below fig-1.10 Page 20
Fig-1.10 PART LIST S.NO PART MBTL PART NUMBER NUMBER DESCRIPTION QTY GRADE 1 90018120000 7402DAP00170N UPPER ASPG MTG ASSY 2-2 91007007400 7402EAP01010N M16-1.5 X 50 HFS 4 GRADE-10.9 3 91007007500 7402EAP01020N M16-1.5 X 55 HFS 8 GRADE-10.9 4 91008001400 7402EAP01030N M16-1.5 HFN 12 CLASS-10 INSTALLATION PROCEDURE: 5.1. INSTALLATION OF HANGER ASSEMBLY AND HANGER CROSSMEMBERASSEMBLY Page 21 Fig-1.11
PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY 1 90018030000 7402EAP00880N HANGER ASSY -LH 1 2 90018040000 7402EAP00890N HANGER ASSY -RH 1 3 90018220000 7402EAP00820N H-H CROSS CHANNEL ASSY 1 4 91007001000 7402EAP00950N M12-1.5 X 35 HFS 18 5 91008000100 7402EAP00970N M12 X 1.5 HF NUT 26 6 90018140300 CROSSMEMBER CHANNEL 1 7 90018140400 CROSSMEMBER MTG CHANNEL 2 8 91007004100 7402EAP00990N M14-1.5 X 45 HFS 20 10 91007001300 7402EAP00960N M12 X 1.5 X 60 HFS 8 11 91008000300 7402EAP01000N M14 X 1.5 HF NUT 20 TORQUE RECOMMENDATION SIZE TORQUE ft-lbs Nm M12 X 1.5 81-110.6 110-150 M14 X 1.5 162-184 220-250 Hanger assy. LH/RH will be in assembled condition. These were connected by H-H Cross Channel (as shown in fig 1.11) using M14 X 1.5 35. (Note that it should not be tighten for adjustment purpose) PROCEDURE: Fig-1.12 1. Locate Item no. 1, 2, & 7 in frame as shown in the figure using M14 x 1.5-45 bolts. (Note that M14 x 1.5 bolts should not be tightened). 2. Place Item no.6 (CROSS MEMBER CHANNEL) in Item no.7 (CROSS MEMBER MTG CHANNEL) using M12 x 1.5-35 HFS at Top & M12 x 1.5-60 HFS at Bottom as shown in the figure.1.12 Tighten the M12 x 1.5 bolts loosely. 3. Once located everything, torque should be applied for all bolts as per chart. Page 22
5.2. INSTALLATION OF LIFT SPRING WITH H H CROSS CHANNEL ASSEMBLY Fig-1.13 Fig1.14 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY 1 90018030000 7402EAP00880N HANGER ASSY -LH 1 2 90018040000 7402EAP00890N HANGER ASSY -RH 1 3 90018220000 7402EAP00820N H-H CROSS CHANNEL ASSY 1 4 91001000200 7402CAP00020N LIFT SPRING 2 5 90014030000 7402EAP00930N M10-1.5 X 20 HHCS 4 6 91008000100 7402EAP00940N M10 INTERNAL TOOTHLOCK WASHER 4 TORQUE RECOMMENDATION TORQUE SIZE ft-lbs Nm M10 X 1.5 14.75-19.9 20-28 PROCEDURE: Place the Item no.4 (LIFT SPRING) in Item no.3 (H-H Cross Channel Assy.) as shown in fig-1.13, 1.14 using M10 X 1.5 bolt. (Note that the over tightening of M10 X 1.5 cause air spring failure). 5.3. INSTALLATION OF UPPER AIR SPRING BRACKET ASSY AND CROSSMEMBER ASSEMBLY Page 23
Fig-1.15 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY 1 90018120000 7402DAP00170N UPPER A/SPG BRACKET ASS'Y 2 2 91007007400 7402EAP01010N M16 X 1.5 X 50 HFS 4 3 91007007500 7402EAP01020N M16 X 1.5 X 55 HFS 8 4 91008001400 7402EAP01030N M16 X 1.5 HF NUT 12 TORQUE RECOMMENDATION TORQUE SIZE ft-lbs Nm M16 X 1.5 247-276.5 335-375 PROCEDURE: 1. Locate Item no.1 in frame as shown in the figure using M16 x 1.5 bolts (Item no. 2 & 3). 2. Finally tighten the M16 x 1.5 as per above torque chart. 5.4. INSTALLATION OF LOWER BEAM ASSEMBLY AND STEER DAMPERS Page 24
Fig-1.16 PART LIST S.NO PART NUMBER MBTLPART NUMBER DESCRIPTION QTY 1 90018180000 7402EAP00860N LOWER BEAM ASSY LH 1 2 90018190000 7402EAP00870N LOWER BEAM ASSY RH 1 3 91007003100 7402EAP01090N M20-1.50 X 90 HHCS 8 4 91008003900 7402EAP01100N M20-1.50 HEX NUT 8 5 91008001400 7402EAP01120N M20 WASHER FLAT 16 6 91002000100 7402GAP00010N STEER DAMPER 2 7 90018140100 TIE ROD ARM LH 1 8 90018140200 TIE ROD ARM RH 1 9 91007002200 7402EAP01040N M18 X 1.5 x 120 HHCS 2 10 91007000500 7402EAP01050N M18 X 1.5 x 110 HHCS 2 11 91008001600 7402EAP01060N M18 X 1.5 NYLON INSERT 4 12 91008002000 7402EAP01070N M18 WASHER FLAT 8 TORQUE RECOMMENDATION SIZE TORQUE ft-lbs Nm M18 X 1.5 258-295 350-400 M20 X 1.5 331.9-354 450-480 1. Turn the LH/RH tire outside to match the uncompressed length of steer damper. 2. Once the required dimension is achieved, the damper end holes has to be matched & bolted with the LBA hole & tie rod arm hole. 3. Torque the fasteners to the specification mentioned in drawing. 4. After fitting the steer damper on LH/RH side, other side tyre has to be turned outside in the same way followed in 1 st step. 5. There will be more force required to turn the tire due to stiffness of steer damper already fitted on one side. Page 25
6. For Ease in turning the tire, one can use long rod or lever for better leverage. The same procedure followed in 1 st step has to be repeated here. PROCEDURE: 1. Locate item no. 1 & 2 in Axle using LBA dowel pin. Bolt it by using M20 X 1.5 90 HHCS loosely. 2. Using M18-1.5 x 110 HHCS bolt place one end of Steer Damper (item no. - 6) in Tie Rod Arm and other end to the Lower Beam assembly (item no. 1 and 2) by using M18-1.5 x 120 HHCS bolt. 3. Once located everything, torque should be applied for all bolts as per chart. 5.5. INSTALLATION OF CONTROL ARMS Fig-1.17 PART LIST S.NO PART NUMBER MBTLPART NUMBER DESCRIPTION QTY 1 90018030000 7402EAP00880N HANGER ASSY -LH 1 2 90018040000 7402EAP00890N HANGER ASSY -RH 1 3 90008040000 7402FAP00030N UPPER CONTROL ARM ASS'Y LH 1 4 90008060000 7402FAP00040N UPPER CONTROL ARM ASS'Y RH 1 5 90008080000 7402FAP00050N LOWER CONTROL ARM ASS'Y 2 6 91007000700 7402EAP01130N M22 X 1.5 X 190 HHCS 8 7 91008003700 7402EAP01140N M22 X 1.5 NYLON INSERT 8 8 91008003500 7402EAP01150N M22 WASHER FLAT 16 9 91001000200 7402CAP00020N LIFT SPRING 2 10 91008000600 7402EAP01110N M20-1.5 NYLON INSERT 2 11 90018180000 7402EAP00860N LOWER BEAM ASS'Y - LH 1 12 90018190000 7402EAP00870N LOWER BEAM ASS'Y -RH 1 13 91005000500 7402EAP00900N WEAR WASHER 16 Page 26
TORQUE RECOMMENDATION SIZE TORQUE ft-lbs Nm M20 X 1.5 NI NUT 45-51.6 61-70 M22 X 1.5 487-545 660-740 PROCEDURE: 1. Locate item no. 3, 4, & 5 (UPPER CONTROL ARM ASSY LH/RH and LOWER CONTROL ARM ASSY) in item no. - 1 & 2 (HNAGER ASSY LH/RH) by using M22 X 1.5 bolt (as shown in fig-1.17). Tighten the bolt loosely. 2. Insert Air spring Combo stud of item no.10 into item no 3 and 4 (UPPER CONTROL ARM ASSY LH/RH as shown in fig-1.17). Tighten the air spring Combo stud using M20 X 1.5 NYLON INSERT as per above torque chart. (Note that the over tightening of M20 X 1.5 NYLON INSERT cause air spring failure). 3. Fix item no. 11 & 12 (LOWER BEAM ASSY'S LH/RH) to the item no. 3, 4 & 5 (UPPER CONTROL ARM ASSY LH/RH and LOWER CONTROL ARM ASSY) using M22 X 1.5 bolt (as shown in fig- 1.18). Fig-1.18 4. Check whether the axle is perpendicular to frame. Measure the distance between left end of the axle and any fixed reference (Drive axle or non-steerable dead axle which are perpendicular to frame) (as shown in fig-5.3). Similarly measure the distance for right end of axle. Page 27 Fig-1.19
5. Adjust the lift axle position (by adjusting the CONTROL ARM ASSY (item no. 3, 4, 5), Lower Beam Assy LH/RH (item no. 11 &12) & HANGER ASSY LH/RH (item no. 1, 2). So that A equal to B. 6. Finally tighten the M22 X 1.5 bolt & M20 X 1.5(Axle Bolts) as per above torque chart. 7. The tag lift axle should be parallel to Rear axle RA1/RA2. To ensure the parallelism & correct location of tag lift axle, (a) The distance (A & B) of (LA) axle center from any fixed reference should be equal on both LH & RH side. The fixed reference can be RA1 or RA2. (b) The distances should be measured on vehicle parked on level surface. (c) Ensure that vehicle is in straight ahead condition prior to measurements. (d) Fine adjustments may be required on LBA, Control arms & hanger to get the distances (A & B) equal on both the sides. (e) The lift axle should be correctly located with respect to Rear axle as per specification. Incorrectly located lift axle results in incorrect load distribution on axles. 5.6. INSTALLATION OF LOAD SPRING Fig-1.2 Fig-1.21 PART LIST S.NO PART NUMBER MBTL PART NUMBER DESCRIPTION QTY 1 90018120000 7402DAP00170N UPPER A/SPG BRACKET ASS'Y 2 2 91001000100 7402CAP00010N LOAD SPRING 2 3 91007005400 7402EAP00910N 3/8-16NC X 1"L HHCS 4 4 91008003400 7402EAP00920N 3/8-WASHER SPLIT LOCK 4 5 91008000200 7402EAP00980N 1/2-13NC NYLON INSERT 2 6 91008000500 7402EAP01080N 3/4-16NF NYLON INSERT 2 Page 28 TORQUE RECOMMENDATION SIZE TORQUE ft-lbs Nm 3/8 14.75-20 20-27 1/2 22-34.6 30-47 3/4 39.8-50 54-68
PROCEDURE: Place item no. 2 (LOAD SPRING) in between LOWER BEAM ASSEMBLY and A/SPG BRACKET ASSY- UPPER (item no.3 & 4). Use above listed fasteners to fix Air spring. The fasteners to be tightened as per above torque chart. (Note that the over tightening of air spring fasteners cause air spring failure). Bushing Replacement & Re-assembly Procedure First chock the wheels and secure the vehicle. Lift the Liftable axle and block up the axle, remove the wheels and deflate the air springs. Dismantle the Main air spring & lift air spring. Dismantle the Control arm s M22 nuts and bolts from LBA Side and then hanger side. And then dismantle the control arms from the Assembly s. Inspect Hanger assembly & LBA Assembly holes and mating surfaces for unusual wear or damage. Repair or replace components as required. Remove the damaged PU bushing and inner metal bushing sleeve from the control arm eye by using press M/C. Clean the bushing eye of corrosion and debris. Apply the soap solution to the new bushing outer diameter surface and inner diameter surface of control arm eye for ease installation. Place the new PU bushing over the control arm eye and then press the PU bushing into the control arm sleeve by using press M/C. And then press the metal bushing sleeve into the PU bushing. During pressing, make sure that PU bushing & Metal bushing sleeve are equally placed in the control arm s eye. After Pressing, Please ensure the dimension as shown in the figure-1.22. Install the new wear washers on both sides of the new bushing and then assemble into the hanger & LBA assembly with new M22X1.5X190mm bolt, M22X1.5 Cleve Lock nut & M22 Washer. And then tighten the M22 Bolt & nut to the torque (780Nm-840Nm). Reassemble the suspension in reverse order from above. (a) The replacement dimension for wear washer is its thickness. (b) The deformation for wear washer is generally non uniform & observed deformation patterns in field are cup shaped. The thickness of washer is 6.35 mm. It has to be replace when the measured thickness is less than 3 mm or washer found to be teared from any direction. (c) The PU bushes are press fitted within control arm sleeves & it is not possible to check its dimensions without its complete removal. (d) However while replacing the wear washer one should check thoroughly the bushings for its physical conditions. It has to be replaced if found teared from any direction.. Fig-1.22 Page 29
10. SPECIAL TOOL REQUIREMENT FOR SERVICING 1. M22 Bolt 33-34 Ring Spanner. (Control arm Fasteners). 2. M22 Bolt 33-34 Box socket. (Control arm Fasteners). 3. Standard tools 6. AFTER ASSEMBLY INSPECTION 1. In lifted condition Static height should be 115.5 mm & in Rebound 451.5mm 2. Reduce the air pressure to the load springs to below 10 psi. Operate the suspension up and down to ensure proper operation and suspension clearance to other components. Check that the driveline has adequate clearance when the suspension is lifted. 3. Check that all fasteners are tightened to the proper torque values. Page 30
8. SERVICABLE PART LIST S.n o Part Number MTBL Part Number DESCRIPTION QTY LH/RH 1 90018180000 7402EAP00860N LBA - LH 1 LH ASSY 2 90018190000 7402EAP00870N LBA - RH 1 RH ASSY 3 90018030000 7402EAP00880N HANGER-LH 1 LH ASSY 4 90018040000 7402EAP00890N HANGER-RH 1 RH ASSY 5 90018220000 7402EAP00820N H-H CROSS CHANNEL ASSY 1 ASSY 6 90008040000 7402FAP00030N UPPER CONTROL ARM ASSY LH 1 LH ASSY 7 90008060000 7402FAP00040N UPPER CONTROL ARM ASSY RH 1 RH ASSY 8 90008080000 7402FAP00050N LOWER CONTROL ARM ASSY 2 ASSY 9 90018120000 7402DAP00170N UPPER ASPG MTG ASSY 2 ASSY 93001000300 7403BAP00050N STANDARD PARTS 1 91001000600 7402CAP00010N LOAD SPRING 2 STD Part 2 91001000200 7402CAP00020N LIFT SPRING 2 STD Part 3 91002000100 7402GAP00010N STEER DAMPER 2 STD Part 4 91006002600 7403BAP00030N EXT.MALE-ELBOW M12X1.5- Ø12 2 STD Part 5 91006001300 7403BAP00040N MALE-ELBOW 1/4" NPT - Ø12 2 STD Part 6 91005000500 7402EAP00900N WEAR WASHER 16 STD Part 7 91005000400 7402FAP00090N BUSHING-URETHANE 8 STD Part 8 90008040100 7402FAP00100N BUSHING-SLEEVE 8 STD Part 92001000600 7402EAP00830N FASTENER KIT- 92001000600 1 91007005400 7402EAP00910N 3/8" - 16NC 1"LG HHCS 4 STD Part 2 91008003400 7402EAP00920N 3/8" - WASHER SPLIT LOCK 4 STD Part 3 91007005300 7402EAP00930N M10-1.5 X 20 HHCS 4 STD Part 4 91008001100 7402EAP00940N M10 - WASHER INTERNAL TOOTH 4 STD Part 5 91007001000 7402EAP00950N M12-1.50 X 35 HFS 18 STD Part 6 91007001300 7402EAP00960N M12-1.50 X 60 HFS 8 STD Part 7 91008000100 7402EAP00970N M12-1.50 HFN 26 STD Part 8 91008000200 7402EAP00980N 1/2" - 13NC NYLON INSERT 2 STD Part 9 91007004100 7402EAP00990N M14-1.5 X 45 HFS 20 STD Part 10 91008000300 7402EAP01000N M14-1.50 HFN 20 STD Part 11 91007007400 7402EAP01010N M16-1.5X50 HFS 4 STD Part 12 91007007500 7402EAP01020N M16-1.5X55 HFS 8 STD Part 13 91008001400 7402EAP01030N M16-HFN 12 STD Part 14 91007002200 7402EAP01040N M18-1.50 X 120 HHCS 2 STD Part 15 91007000500 7402EAP01050N M18-1.50 X 110 HHCS 2 STD Part 16 91008001600 7402EAP01060N M18-1.50 NYLON INSERT 4 STD Part 17 91008002000 7402EAP01070N M18-WASHER FLAT 8 STD Part 18 91008000500 7402EAP01080N 3/4" - 16NF NYLON INSERT 2 STD Part 19 91007003100 7402EAP01090N M20-1.50 X 90 HHCS 8 STD Part 20 91008003900 7402EAP01100N M20-1.50 HEX NUT 8 STD Part 21 91008000600 7402EAP01110N M20- NYLON LOCK INSERT NUT 2 STD Part 22 91008000800 7402EAP01120N M20- WASHER FLAT 16 STD Part 23 91007000700 7402EAP01130N M22-1.50 X 190 HHCS 8 STD Part 24 91008003800 7402EAP01140N M22-1.5 NYLON INSERTS 8 STD Part 25 91008003500 7402EAP01150N M22- WASHER FLAT 16 STD Part Page 31
8. MAINTENANCE SCHEDULE Sr No Nature of work Frequency (Km) 1 Hub greasing for tag axle with replacement of oil seal, Adjust hub play 30000 2 Check for excessive king pin play,stub axle play adjust if required 30000 3 Check for excessive wear of king pin bush replace if required 30000 4 Check condition of brake drum & brake liner replace if required 30000 5 Wheel alignment on electronic wheel aligner 10000 6 Load sensing valve link rod adjustment 10000 7 Replace the kit of actuation valve like PLV,GRV, load sensing valve Once in a 2 years 8 Check & tighten the all hardware of the lift axle structural members Daily 9 10 Check for any fouling or intersecting of components in lift as well as in nonlift condition Check condition of steering dampers, rubber mountings, oil leakage replace if required Daily 30000 11 Check condition of lift bellow 30000 12 Check condition of load bellow 30000 13 Check for any air leakage in actuation system Daily 14 Check for any leakage in bellows Daily 15 Check for any welding breakage in structural members Daily 16 Check wear washers condition for the wear, replace if required 30000 17 Check condition of rubber bushing for wear, replace if required 30000 18 Check & tighten the all hardware of the lift axle structural members after first trip & then every 10000 km 10000 19 Check tyre pressure Daily 20 Tyre rotation 10000 21 Check lift axle operation before the trip Daily 22 Check operational switch fitted in cabin or cowl Daily Page 32
9. PREVENTIVE MAINTENANCE DAILY Check for loose or broken parts on or around suspension to prevent any serious problems from occurring. EVERY 30 DAYS Check clearances around all moving suspension parts, air springs, tires and shock absorbers. Any signs of interference should be immediately corrected. Visually inspect axle beam bolted connection to make sure bolts are tight and there are no signs of wear. EVERY 90 DAYS & WITH ANNUAL INSPECTION Inspect items required in daily and 30-day inspections. Inspect all welded connections Inspect all pivot and clamping connections such as the suspension pivots and shock mounts. Trouble shooting - Sr no Failure Reason Remedy Not getting desired load Improper air pressure to load air spring Inflate with correct air pressure 1 on the axle suspension mounted improperly Check for the correct mounting 2 In sufficient air pressure in the system 3 Not getting correct lift 4 Axle shimmy 5 Tyre wear Defective air compressor- air inflation in the system Leakage in layout circuit Lift air bags not getting proper air pressure Load sensing valve setting defective Layout circuit defective Toe setting is incorrect Pivot bolt loose Tyre uneven wear Leakage in steer damper King pin shims excessive play Toe setting is incorrect steer damper setting incorrect Steer damper bush weared off Excessive wear in wear washers & bushings of control arm Insufficient tyre pressure Loose control arm hardware Excessive play in king pin shims & bushes Lift axle lifted in partial condition Check air compressor for building the air pressure Check leakage & rectify Check the actuation circuit & rectify Adjust to 105 mm Rectify Correct with 1-3 mm toe in setting / for lift axle adjust -1.5 to - 3.5 mm (toe out) Tightened the loose bolt Check for tyre wear & rectify Replace the steering damper Rectify Adjust Adjust Replace the steering damper Replace Correct Rectify Rectify Rectify Page 33
Actuation system Actuation system Knorr Bremse Circuit diagram - Lift axle load sensing mechanism Load sensing valve is supplied by Wabcco is fitted in between rear tandem axle. Page 34
The link rod position in unladen condition will be horizontal as shown in fig below. In laden condition it will be angular with approximate angle of 24 degree. Page 35
In case we require to adjust the length of load sensing mechanism it is as per below dimension. 105 mm +2 /-1 mm Wheel Alignment Carry out the wheel alignment at every 10000 km on electronic wheel aligner with tyre rotation as per below. Toe value for front 2 axle 1 to 3 mm (Set toe in value viewing from vehicle front) Toe value for rear tag lift axle is -1.5 to - 3.5 mm (Set toe out value viewing from vehicle front) Page 36
For electronic wheel alignment data Camber angle Caster angle Toe value Parallelism ( Applicable to Truxo31& 37) Scrub angle ( Axle skewness value) Thrust angle ( Axle perpendicularity with Chassis) Toe value for tag lift axle for Truxo 37-0.25 to + 0.75 degree 3 to 4 degree 1 to 3 mm +/- 5 minute +/- 5 minute +/- 5 minute -1.5 to -3.5 mm (toe out) 12. DO S and DON T S in lift axle: DO s: 1. Ensure that Lift axle automatically lifted when truck is travelling in reverse condition. 2. Lift the lift axle in traction loose condition with manual override switch. 3. Always check state laws in all states through which you will be traveling for legal allowable weight and axle configuration. 4. Check lift axle fasteners torque as per specification before delivery of vehicle to customer. 5. Ensure that Max cut screw setting on LA as per specs. 6. When performing maintenance on LA, ensure that air is not supplied to the air springs. Component damage, bodily injury can otherwise result. 7. When operating your lift axle, ensure that all personnel are at safe distance from the actuating lift axle. 8. Be careful during suspension operation as suspension components move at a rapid rate. 9. Regularly check for Critical fasteners Torque's as per spec. DON T: 1. Don t lift the lift axle in laden condition. 2. Don t temper front / rear suspension. 3. Don t tamper pneumatic components such as Pressure Control Valve, Load Sensing Valve linkage. Page 37
4. Suspensions are designed to operate within specific parameters. Operating the suspension outside the design parameters may result in improper performance, damaged equipment, and void of warranty. 5. Don't over torque Air spring assy. mountings this will lead to failure of air springs. 6. Don't over torque steer damper mountings this will lead to crushing of shock inner sleeves Page 38