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Chalmers Suspension International 800 Series Service Manual

Tandem truck suspensions 65,000 – 100,000 lb
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800 SERIES HEAVY DUTY
SERVICE MANUAL
65,000 – 100,000 LB
PART# EDOC002
CHALMERS SUSPENSIONS INTERNATIONAL INC
6400 NORTHAM DRIVE, MISSISSAUGA
ONTARIO, CANADA
L4V 1J1
(905) 362-6400 VOICE
(905) 362-6401 FAX
OUR EDGE IS OUR PRODUCT

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Summary of Contents for Chalmers Suspension International 800 Series

  • Page 1 800 SERIES HEAVY DUTY SERVICE MANUAL 65,000 – 100,000 LB PART# EDOC002 CHALMERS SUSPENSIONS INTERNATIONAL INC 6400 NORTHAM DRIVE, MISSISSAUGA ONTARIO, CANADA L4V 1J1 (905) 362-6400 VOICE (905) 362-6401 FAX OUR EDGE IS OUR PRODUCT...

  • Page 2: Table Of Contents

    Contents Page No. GENERAL INFORMATION……………………………………… INTRODUCTION TO THE SUSPENSION……………………… SUSPENSION PART NAMES……………………………… SERVICE – INSPECTION REQUIREMENTS…………………. GUIDELINE TO THE INSPECTION AND REPLACEMENT OF SERVICE PARTS…………………………. FASTENERS………………………………………………….. TORQUE ROD BUSHING INSPECTION…………………. TORQUE ROD BUSHING REPLACEMENT……………… RESTRICTOR CAN INSPECTION………………………… RESTRICTOR CAN REPLACEMENT…………………….. SPIGOT CAP INSPECTION…………………………………...
  • Page 3 APPENDIX “A”……………………………………………………. APPENDIX “B”……………………………………………………. APPENDIX “C”…………………………………………………….

  • Page 4: General Information

    GENERAL INFORMATION This manual is to be used for the service of a Chalmers 800 Series Tandem Suspension 65,000 to 100,000 lbs capacity and is intended to give guidance and recommendation for the care, maintenance, inspection and safe operation of the above suspension. It is not a replacement for existing or future specific Pre-Delivery Inspection (P.D.I.) &...

  • Page 5: Introduction To The Suspension

    The 800 Series is available in 60” and 65” axle spacing for the 65,000 lbs capacity and in 65” axle spacing for the 80-100,000 lbs capacity. The axle spacing and capacity is included as part of the suspension name, e.g.
  • Page 6 SUSPENSION NOMENCLATURE FIGURE 1A (65,000 lbs suspension shown)
  • Page 7 SUSPENSION NOMENCLATURE FIGURE 1B (80-100,000 lbs suspensions shown)

  • Page 8: Service - Inspection Requirements

    3.0 SERVICE – INSPECTION REQUIREMENTS The Chalmers 800 Series Suspension was designed to require minimum general maintenance. The recommendations shown on the following chart are precautionary and are aimed at avoiding future problems. 1000 Mile PART ACTION P.D.I. 1600 KM...
  • Page 9 1000 Mile PART ACTION P.D.I. 1600 KM YRLY Walking Inspect for wear and cracks. See Beam Sections 4.8 & 4.9 for guidelines. Inspect for beam free float in axle saddles, 1.75” (45mm) fore and aft. .38” (10mm) side to side. See Section 4.8.

  • Page 10: Guideline To The Inspection And Replacement Of Service Parts

    GUIDELINES TO THE INSPECTION AND REPLACEMENT OF SERVICE PARTS Recommended tools needed to carry out the work covered in Section 4.1 through 4.13. TOOL LIST Open End Wrench: 9/16”, 3/4”, 15/16”, 1-1/8”, 1-5/16” Box Wrench (Offset Preferred): 9/16”, 3/4”, 15/16”, 1-1/8”, 1-5/16”. Standard Socket (1/2”...

  • Page 11: Fasteners

    FASTENERS This guideline is to be used for the inspection or replacement of Chalmers supplied fasteners ONLY. Not supplied by Chalmers are the fasteners attaching the triangular frames and upper frame brackets to the vehicle frame. For inspection and specification on these, please refer to the vehicle manufacturer. The fastener systems used in a Chalmers suspension are the key to the care and safe operation of the suspension.

  • Page 12: Torque Rod Bushing Inspection

    VEHICLE CONTROL. TORQUE ROD BUSHING INSPECTION. All 800 Series Suspensions incorporate rubber bushed torque rod joints that isolate the vehicle from axle braking and driving shocks. The Chalmers bushings absorb axle shock by compression. This compression may give a false impression of a worn bushing. To...
  • Page 13 * Service Bushing NUMBER “2” JOINT ASSEMBLY STANDARD BASE #2 Joint (800021 Base) 800 Series Tandem Truck 65,000 lbs. Capacity (all Rods) & 80-100,000 lbs. Capacity (upper Rods). #2 Joint (02P00141 Base) 800 Series Tandem Truck 80-100,000 lbs. Capacity (lower Rods).

  • Page 14: Torque Rod Bushing Replacement

    TORQUE ROD BUSHING REPLACEMENT Replacement of Chalmers Torque Rod Bushings may be achieved easily and quickly in any shop without the use of a press or special tools, using the following steps as a guide. STEP 1 – If possible power wash the torque rod ends, as a minimum, the ends should be brushed with a hard bristle brush to remove road dirt accumulations.
  • Page 15 STEP 8 – Liberally lubricate the inside diameter of the torque rod eye, and the outside diameter of the replacement rubber bushing with a quality rubber lubricant such as Rimslip or equivalent. IMPORTANT: Never use any mineral based oils, greases, jellies or solvent soaps as a lubricant.
  • Page 16 STEP 11 – Press the spigot caps into the ends of the torque rod bushings, secure the ends in place using new 5/8” NC fasteners. Torque the 5/8” NC fasteners to 135 ft. lbs. See Table 2. **IMPORTANT: Failure to check torque may lead to fastener failure and consequent loss of vehicle control and void warranty.
  • Page 17 TORQUE ROD INSTALLATION UPPER TORQUE RODS #05S00004 65,000 LBS CAPACITY SUSPENSION UPPER TORQUE RODS #805131 80,000 to 100,000 LBS CAPACITY SUSPENSION FIGURE 4...

  • Page 18: Restrictor Can Inspection

    RESTRICTOR CAN INSPECTION The Chalmers spring system comprises of a rubber spring and an enclosing metal restrictor can. The purpose of the restrictor can is to provide specific ride, road handling characteristics and protection to the spring. To accommodate the different road handling conditions that may be encountered, Chalmers produces a number of different sized restrictor cans.
  • Page 19 NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES. STEP 3 – Remove the four (or three) 5/8” NC fasteners holding the lower spring plate to the beam.

  • Page 20: Spigot Cap Inspection

    SPIGOT CAP INSPECTION The spigot caps are part of the Chalmers torque rod joint system and play a key part in this system by placing a small amount of end compression to the rubber bushing and providing end retention to the joint. The suspension capacity and spigot cap used is shown in the following Table 3.

  • Page 21: Walking Beam Inspection

    WALKING BEAM INSPECTION The Chalmers 800 Series Walking Beam is a key part of the load support and equalization system of the suspension. It not only acts as a lower support and anchor point for the spring system, but also provides the means to equally share the vehicle load to the axles.

  • Page 22: Walking Beam Repair/Replacement

    NOTICE: Should excessive wear or cracks be found during vehicle operations, it may be SLOWLY driven to the nearest repair shop. Failure to repair or replace excessively worn or cracked walking beams will lead to failure of the beam ends and consequent loss of vehicle control.
  • Page 23 STEP 3 – Lift the rear of the vehicle. Support the frame on stands so all weight is just taken off the suspension. NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES.

  • Page 24: Saddle Inspection

    4.10 SADDLE INSPECTION The Chalmers 800 Series Saddles have been designed with three “wear” pads intended to prolong the life of the Chalmers Walking Beam. See Fig 8. These pads, located below the beam and to each side, are designed to wear down over time and be replaced. The rate of wear on these pads will vary depending on the operating conditions, axle loading and distance travelled.

  • Page 25: Rubber Spring Inspection

    The rubber springs are factory matched to the capacity of the suspension to provide the best ride possible. Three sizes are used in the 800 Series and are shown in Table 4. TABLE 4...

  • Page 26: Rubber Spring Replacement

    STEP 7 – Install and tighten the new 5/8’” NC spring plate fasteners. Torque to135 ft. lbs. See Table 2. AXLE ALIGNMENT The 800 Series Tandem Suspension uses four torque rods for each axle. These torque rods are the ONLY parts in the suspension that affect the location or alignment of each axle.

  • Page 27: Axle Measurement

    The Chalmers 800 Series Suspension allows for the precision alignment of each axle by the use of fine threads cut into the bottom torque rod tubes. These rods incorporate left and right hand cut threads on the same tube, thus by rotating the tube, the rod length may be increased or decreased (within the limit of the rod) to achieve the desired alignment.
  • Page 28 STEP 3 – Using a relevant alignment system and following all the manufacturers operating and safety instructions, take measurements of the axle alignment. Compare these to the vehicle manufacturers specification. If none are available, the following may be used as a guide: For Hunter type equipment - .08 deg.
  • Page 29 AXLE ALIGNMENT ( NO ALIGNMENT SYSTEM ) FIGURE 9...

  • Page 30: Axle Alignment Adjustments

    5.2 AXLE ALIGNMENT ADJUSTMENTS Should the results of Step 3 or 4 from Section 5.1 show that the axles are not within either the vehicle manufacturers specifications or the Chalmers recommended guidelines, an axle adjustment will be required. This may be done without the use of any special tools using the following steps as a guide.
  • Page 31 FIGURE 10...

  • Page 32: Trouble Shooting

    6.0 TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE AND CORRECTION (Fasteners Not Torqued Properly) Loose Spigot Caps Re-torque to 135 ft. lbs. And re-check at 1,600 km/1,000 miles. If repeated loosening occurs, replace fasteners & spigot cap if required. Torque to 135 ft. lbs.
  • Page 33 PROBLEM POSSIBLE CAUSE AND CORRECTION Vehicle Does Not Sit Level (Broken or Missing Restrictor Can) Replace both restrictor cans. See Sections 4.4. & 4.5. (Damaged Spring) Replace spring. See Sections 4.11 & 4.12. (Damaged Walking Beam) Replace walking beam. See Sections 4.9. (In a New Vehicle High/Low Beam Installation Problem) Replace incorrect beam.
  • Page 34 The smaller of the two dimensions is to be taken as the wear limit. See Table 6 for values. NOTE: If spigot is below min. dimension shown in Oversize Table, contact Chalmers for guidelines. #2 Joint 800 Series Tandem Truck 60,000 to 100,000 lbs Capacity...
  • Page 35 APPENDIX “A” Restrictor Can Available and Application Chart 65,000 lbs to 80,000 lbs Style 100,000 lbs Style TRUCK SUSPENSION MODEL Restrictor Part No. Usage by Standard Comments Can# Model/Capacity Optional 373032 4.44” 14.19” 0.188” 800-XX Series Std. Tandem 65-80,000 lbs. Axle 26 HD 07S00001 4.62”...
  • Page 36 APPENDIX “B” REPAIR & WELD INSTRUCTIONS Walking Beam Ends Scope: This procedure shall be used when repairing and welding Chalmers Suspensions International Inc. walking beam-ends. Safety: The following safety instructions must be read and followed. Failure to do so could lead to serious injury or possible loss of life. Prior to any work commencing on the vehicle, the cargo compartments and delivery systems must contain a non-explosive and non-toxic atmosphere.
  • Page 37 MANUAL SHIELDED ARC PROCESS: Thickness 1/4” 3/8” Type 7018 7018 Electrode Size 1/8” 1/8” Amperage Voltage Weld Speed I.P.M. Preheat to room temperature, 70 – 110 deg.F. Number of passes depends on type and size of joint. METAL – INERT GAS PROCESS: Thickness 1/4”...
  • Page 38 Inspection: Visually inspect every completed row. Repair: Prior to any repair work, read all safety notes in Section 2.0. Prior to any installation, support the vehicle on stands, apply brakes and block wheels. Prior to any welding, read all general notes and welding process in Sections 3.0, 4.0, 5.0 and 6.0.
  • Page 39 APPENDIX “C” REPLACEMENT & WELD INSTRUCTIONS Saddle Wear Pads Scope: This procedure shall be used when replacing and welding Chalmers Suspensions International Inc. saddle wear pads. Safety: The following safety instructions must be read and followed. Failure to do so could lead to serious injury or possible loss of life.
  • Page 40 MANUAL SHIELDED ARC PROCESS: Thickness 1/4” 3/8” Type 7018 7018 Electrode Size 1/8” 1/8” Amperage Voltage Weld Speed I.P.M. Preheat to room temperature, 70 – 110 deg.F. Number of passes depends on type and size of joint. METAL – INERT GAS PROCESS: Thickness 1/4”...
  • Page 41 Inspection: Visually inspect every completed row. Repair: Prior to any repair work, read all safety notes in Section 2.0. Prior to any installation, support the vehicle on stands, apply brakes and block wheels. Prior to any welding, read all general notes and welding process in Sections 3.0, 4.0, 5.0 and 6.0.
  • Page 42 Saddle – Old Wear Pads Removed Side Wear Pad Cam Wear Pad Side Wear Pad 3/16” Fillet Weld on ends of Side Wear Pads only 3/8” Fillet Weld on ends of Cam Wear Pad only Figure 1...

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