Ace ART-60 Series Operating Instructions Manual

Table of Contents

Quick Links

Download this manual

OPERATING INSTRUCTIONS

GENERAL MAINTENANCE

WHEN ORDERING YOUR PARTS, SPECIFIES MODEL NUMBER, PART NUMBER AND

SERIAL NUMBER LISTED BELOW.

ART-60

Series

IMPORTANT

KEEP THIS MANUAL FOR FUTURE REFERENCE.

Study these instructions before operating and/or maintenance of this equipment

FACTORY:

BROTHER EQUIPMENT INC.

1335 East 171

Street

CLEVELAND, OHIO 44110

PHONE 216/458-0180

FAX 216-458-0330

www.theACEadvantage.com

sales@theACEadvantage.com

Table of Contents

Chapters

Table of Contents

Summary of Contents for Ace ART-60 Series

Page 1 OPERATING INSTRUCTIONS GENERAL MAINTENANCE WHEN ORDERING YOUR PARTS, SPECIFIES MODEL NUMBER, PART NUMBER AND SERIAL NUMBER LISTED BELOW. ART-60 Series IMPORTANT KEEP THIS MANUAL FOR FUTURE REFERENCE. Study these instructions before operating and/or maintenance of this equipment FACTORY: BROTHER EQUIPMENT INC. 1335 East 171 Street CLEVELAND, OHIO 44110...
Page 2 Ace Distributor in your locality. INSTRUCTIONS FOR ORDERING REPLACEMENT PARTS For ease in ordering of Ace parts, a system of part and assembly numbers is used. It’s important these numbers be used whenever and wherever possible.
Page 3 TO OR ARISING OUT OF THE EQUIPMENT, PRODUCTS OR SERVICES OF ACE EQUIPMENT SALES. NOTWITHSTANDING ANY OTHER PROVISIONS HEREOF, IN NO EVENT SHALL ACE EQUIPMENT SALS BE LIABLE IN CONTRACT, TORT OR EQUITY FOR ANY LOSS OF ANTICIPATED PROFITS, LOST SALES, INJURY TO PERSONS OR...
Page 4 PROPERTY, LOSS BY REASON OF PLANT SHUTDOWN, NON-OPERATION OR INCREASED EXPENSE OF OPERATION, SERVICE INTERRUPTIONS, CLAIMS OF CUSTOMERS, COST OF MONEY, LOSS OF USE OF CAPITAL OR REVENUE, OR FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL LOSSES OR DAMAGES OF ANY KIND WHATSOEVER. All claims shall be processed through the Brothers Equipment Customer Service Department or your authorized Brothers Equipment dealer.
Page 5 Accordingly, anyone who uses service procedures or tools which are not recommended by Ace must first satisfy himself thoroughly that neither his safety nor the product safety will be jeopardized by the method he selects.
Page 6 Failure to operate as instructed could result in serious damage to the machine, and result in death or serious injury to operator, helpers, and/or bystanders Manuals can also be obtained from ACE EQUIPMENT SALES. WARNING Do Not Drive Or Operate Machinery or Equipment when intoxicated...
Page 7 WARNING! If used incorrectly, this equipment can cause severe injury. Those who use and maintain this equipment should be trained in its proper use and warned of its dangers. THIS ENTIRE MANUAL SHOULD BE READ BEFORE ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT.
Page 8 Section 1 Introduction This manual has Operation, Maintenance, and parts Lists information for Ace model ART-60 frameless rolloff trailers. It’s been prepared to acquaint you with the design features of the unit, and to instruct you in it’s proper operation and maintenance. The ART-60 models are specialized equipment and should be treated with care.
Page 9 General Information The Frameless Rolloff trailer provides a loading and unloading of scrap, solid waste, sludge, etc., for many of the collection and hauling companies. The ART-60 Trailer(s) allows the hauler to load and unload a container safely, easily and effectively.
Page 10 position. Slide the tilt frame back for the suspension to be in the loading and dump position. Relock the airlocks. 1.3.5 Landing Gear Two speed landing gear mounted on tilt frame rated at 120,000 static load with sand pads. 1.3.6 Winch Winch is two speed hydraulic winch 70,000 lb.
Page 11 Rolloff Trailer Load operation (general) Note: There is not possible way to step by step every possible way to use Ace’s equipment below is general operation, Please use good judgment when operating equipment *** Important*** Make sure equipment is on level solid ground, and container is properly loaded. Do not attempt to load, unload or dump container on unlevel ground or uneven container load.
Page 12 4a) ART-60-BT dump the air out of rear axle. Raise any lift axles before loading 5) Extend stinger tail (optional). 6) Raise lift cylinder, extend lift cylinder till the stinger or end of frame lightly touches the ground. 7) Unwrap winch and hook on end of container 8) In low speed, coil cable tilt tight.
Page 13 Air Locks Air locks keep suspension from moving while in operation. ART-60 – Air locks are located at front suspension. ART-60-BT – Air lock located at king pin plate on front trailer. Sliding Suspension ART-60 Unlock air lock and slide suspension backward or forward in a straight line. The suspension has front stop and rear stops.
Page 14 Section 3 Maintenance General Maintenance people whose job is the upkeep of this equipment should have a basic understanding of the equipment and normal sequence of operation. Maintenance in this section is divided into two parts – Preventative Maintenance and Corrective Maintenance (Troubleshooting).
Page 15 Check cable for fraise and splits Lubricate air pin locks daily. Grease ALL pulleys and ALL pivot pins weekly Do’s and Don’ts of Trailer Don’ts Do not lift, dump, load or unload when suspension is extended. Do not travel with stinger tail out. Do not jerk cable when loading or unloading as cable may snap and break.
Page 16 Fill the system with new oil suitable and recommended for use in circuits involving Ace Equipment Sales Inc. cylinders with the following specifications. These suggestions are intended as a guide only. When purchasing hydraulic oil, show these specifications to your oil supplier for final oil recommendations.
Page 17 Stability of physical and chemical characteristics. High demulsibility (low emulsibility) for separation of water, contaminants and air. Resistant to the formation of gums, sludges, acids, tars and varnishes. High lubricity and film strength. Notice Never use a detergent oil, crank case drainings, kerosene, fuel oil, or any non-lubricating fluid (such as water) in the hydraulic system.
Page 18 Over pressurizing the cylinder can cause severe injury or death and/or damage to the unit and cylinder. Do not operate the cylinder at pressures greater than 2,000 P.S.I. unless otherwise approved in Ace Equipment Sales, Inc. WARNING! Worn or damaged hydraulic hoses can cause severe injury or death and/or damage to the unit and cylinder.
Page 19 forward Airbags won't inflate No air Fill air tank Loose Line Fix line Levelers in up position Adjust lever rods Won't dump air Pilot valve closed Check valve Air leak Fix air line Failure to lift cylinder No Oil Check Oil Blown packing Replace packing Busted line...
Page 20 If warranty is granted, Part and service will be shipped C.O.D. Damaged parts must be returned within 30 days for credit to be issued. If Part is not returned within 30 days, Ace has the right to reject any unreturned part, and customer is responsible for invoice.
Page 28 Minimum Requirements for Wet line kit for ART-60-40 Ace Rolloff Trailer Pump 50 to 60 GPM @ 1300rpms 70 Gallon Oil Tank with sight gauge Inline pressure relief return back to tank set @ 2,500psi 1” Pressure 2500psi 1” NPT 10ft 1”...
Page 29 T:\DAT7461.dwg 1 of 2...
Page 30 Stabilizer Frame Assembly Item Part Description 17-3011 Fifth Wheel Plate 17-3016 Guide Plate 48-3008 Main Pin 40-3007 Collar 9-1005 Landing Gear Assy P-S 9-3011 Stabilizer Frame ** 48-3009 Hinge Pin D-Plate Stabalizer 9-3012-2 assembly Right (D-S) D-Plate Stabalizer 9-3012-1 assembly Left (P-S) 9-1006 Landing Gear Assy D-S ** Specify Trailer length and model number...
Page 31 Reeving Cylinder Assy Part Item Description Number Reeving Cage 350-3001 Pulley Blocks 48-3010 Pulley Block Pin 1-3007 Reeving Cylinder ** 48-3011 Cylinder Pin 48-3004 Pulley Pin 72-3020 10" Pulley ** Specify length and model of trailer Brothers Equipment Inc. The information contained in this drawing is for illustrated purpose only, Brothers Equipment reserves the right to 1335 East 171st Street,Cleveland, Oh.
Page 32 MATERIAL See Details DESC. THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE FRACTIONS: 1/16 PROPERTY OF ACE EQUIPMENT SALES INC. ANY REPRODUCTION ANGLES: 80-3004-1 WEIGHT 30 lb. PART NO. IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF .XX:...
Page 33 General Cable Routing ART-60 TOLERANCES SPECIFIED DIMENSIONS FRACTIONS: 1/16 THE INFORMATION CONTAINED IN THIS DRAWING IS THE MATERIAL SOLE PROPERTY OF ACE EQUIPMENT SALES INC. ANY ANGLES: ARE IN INCHES REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE .XX: .015 WEIGHT PART NO.
Page 34 WARRANTY COVERAGE Hutchens Industries, Inc. (“Hutchens”) warrants, except with respect to leaf springs and pneumatic components, to the first purchaser only, that parts, suspension components and units sold by Hutchens will be free from defects in material and workmanship under normal and intended usage and service and proper operation for a period of five (5) years from the date of shipment.
Page 35 Warranty Information Warranty Custom Hoists, Inc. warrants only products of its manufacture against operational failure caused by defective materials or workmanship which occur during proper and normal use within 24 months from the date of purchase from Custom Hoists, Inc. Custom Hoist, Inc. reserves the right to determine what is proper and normal use.
Page 36 Custom Hoists, Inc. shall not be liable for loss of time, manufacturing costs, labor, material, loss of profits, incidental, special or consequential damages, direct or indirect, because of defective products, whether due to claims arising under the contract of sale or independently thereof, and whether or not such claim is based on contract, tort or warranty.
Page 37 SAFETY PRECAUTIONS FOR DOUBLE-ACTING TELESCOPIC CYLINDER WARNING! Rollover or lateral tilt can cause severe injury or death and/or damage to the unit and cylinder. The hydraulic cylinder will not prevent the unit from rollover or lateral tilt. • The cylinder is strictly a lifting device and is not a structural member of the unit.
Page 38 rapidly and possibly cause high pressure trapped oil on the retract side of the cylinder. On roll-off units, do not pull a container onto the hoist until the lift • cylinder(s) are completely extended. On roll-off units, care must be taken if a unit is moved with the lift cylinders extended.
Page 39 Custom Hoists - cylinder ops To Extend: High pressure oil from the pump is directed by the control valve through port (A) to fill the cylinder. Any air in the hydraulic system will be trapped in the end of the cylinder (B) and may be bled off through the bleeder valve (C).
Page 40 Custom Hoists - instr2 We recommend field service repairs be limited to replacement of packing, bushings and wipers with initial setting of head nuts as described in this section. Before servicing the unit, check the plungers for damage. If the plunger is scored or scratched, smooth out marks with a fine stone or emery cloth to avoid damage to the new seals.
Page 41 Custom Hoists - instr2 Step 1 - Parts Identification Figure 1 The cylinder is best serviced mounted in the vertical position, for both disassembly and assembly. Also, it is best located where a hoist can be used directly overhead of the cylinder for removing the plungers if complete disassembly is required.
Page 42 Custom Hoists - instr2 All head nuts are secured to the plunger by a set Figure 4 screw. Under the set screw is a nylon slug to protect the plunger threads.To remove the head nut, the set screw must be loosened using an allen wrench.
Page 43 Custom Hoists - instr2 Reassembly of Cylinder All bores in the packing area and plunger outside diameters must be free of tool marks and scratches. Polish with a fine paper, crocus cloth or a Scotch Brite pad. All parts should be 5/32"...
Page 44 Custom Hoists - instr2 Used for: Installing Packing Back to top Request a Quote Company Profile Technical Service Distributor Finder Products Contact Us Literature Warranty Info What's New Custom Hoists, Inc. P.O. Box 98 | Hayesville, OH 44838 Phone: 1.800.837.4668 | Fax: 1.800.224.6478 http://www.customhoists.com/technical_service/instructions/instr2/instr2.html (6 of 6) [9/13/2007 2:08:08 PM]...
Page 45 Custom Hoists - assembly Tool Kits (Part No: 1-TK-1) Used to install packing, remove retainers and spacers. Chain Wrench with add'l Chain (Part No: 1-CW-19) Used to tighten and remove head nuts. Strap Wrench (Part No: 1-TL-19) To hold plungers from turning during assembly or disassembly.
Page 46 Custom Hoists - assembly Pushers For installing plunger stops, spacers and new style retainers 3" Tubes (Part No: 2-TL-21-3) 4" Tubes (Part No: 2-TL-21-4) 5" Tubes (Part No: 2-TL-21-5) 6" Tubes (Part No: 2-TL-21-6) 7" Tubes (Part No: 2-TL-21-7) 8" Tubes (Part No: 2-TL-21-8) 8-1/4"...
Page 47 Custom Hoists - cylinder opd Extending To Extend: High pressure oil is directed by the control valve into extend port (A). The oil passes through an inner (transfer) tube in the smallest plunger to the base of the cylinder. The pressure acts on the effective area of the largest piston (F) and extends all stages to the first plunger stop.
Page 48 Custom Hoists - cylinder opd To Retract: High pressure oil is directed by the control valve into retract port (B). The pressure is applied to the effective area of the smallest plunger (D) which retracts first. Each stage from the smallest to the largest retracts in its turn.
Page 49 Custom Hoists - instr2 Serial Numbers 400,000 and above Warning Step 1 - Parts Identification Step 2 - Set Screws Step 3 - Head Nuts Step 4 - Bushings Step 5 - Packing, Wave Spring, Lower Bushing Step 6 - Retainer Rings Reassembly of Cylinder Step 7 - Setting Head Nuts Typical Tool End Shapes...
Page 50 Custom Hoists - lifting Individual plunger lifting capacities, multiple stage cylinders. Click the links below for samples. "400" Series Single-Acting Telescopic Cylinders "700" Series Single-Acting Telescopic Cylinders Double-Acting Telescopic Cylinders Extend Capacities of Piston Rod Cylinders Retract Capacities "400" Series Single-Acting Telescopic Cylinders Specific Operating Pressures Plunger Cross...
Page 51 Custom Hoists - lifting Bore (Piston) Cross Plunger Cross 1,500 PSI 1,800 PSI 2,000 PSI Diameter (in.) Sectional Diameter (in.) Sectional (lbs.) (lbs.) (lbs.) Area (Sq. In.) Area (Sq. In.) 2-1/2 4.90 3.14 7,350 8,820 9,800 3-1/2 9.62 7.06 14,340 17,316 19,240 4-1/2...
Page 52 Custom Hoists - lifting 19.63 sq. in. Bore (5" dia.) C.S. area - 3.14 sq. in. Rod (2" dia.) C.S. area 16.49 sq. in. Difference x 1800 p.s.i. Desired operating pressure 29,682 lbs. Retract capacity Request a Quote Company Profile Technical Service Distributor Finder Products...
Page 53 Custom Hoists - oil All internal cylinder parts are lubricated by hydraulic oil in the circuit. Particular attention must be paid to the condition and level of the oil in the circuit. Dirty oil is one of the main causes of hydraulic component failure resulting in expensive downtime.
Page 54 Custom Hoists - oil Reservoir capacity should equal, in gallons, the pump output in G.P.M. or the total G.P.M. of all pumps where there is more than one in the system. Oil operating temperature should not exceed 200°F (93°C) with a maximum of 180°F (82°C) usually recommended.
Page 55 Custom Hoists - oil tars and varnishes. High lubricity and film strength. Notice Never use a detergent oil, crank case drainings, kerosene, fuel oil, or any non-lubricating fluid (such as water) in the hydraulic system. Back to top Request a Quote Company Profile Technical Service Distributor Finder...
Page 56 Custom Hoists - safety single WARNING! Rollover or lateral tilt can cause severe injury or death and/or damage to the unit and cylinder. The hydraulic cylinder will not prevent the dump body or trailer from rollover or lateral tilt. The cylinder is strictly a lifting device and is not a structural member of the unit.
Page 57 Custom Hoists - safety single The operator should stay at the controls during the entire dumping operation. If the body starts to lean, the operator should immediately lower the dump body or trailer. It is important to slowly position the cylinder control valve into the hold position to avoid subjecting the cylinder to high pressure.
Page 58 Custom Hoists - safety single Over pressurizing the cylinder can cause severe injury or death and/or damage to the unit and cylinder. Do not operate the cylinder at pressures greater than 2,000 P.S.I. unless otherwise approved in writing by Custom Hoists, Inc. WARNING! Worn or damaged hydraulic hoses can cause severe injury or death and/or...
Page 59 Custom Hoists - service items Procedure for adjusting headnuts on telescopic cylinders . Bleeding air from Single-Acting Telescopic Cylinders. Packing, wipers and bushings are considered normal service or replacement items. These items are subject to contamination from external and internal foreign materials, many of which are abrasive in nature, causing abnormal wear or damage to the parts, to the extent replacements are required.
Page 60 Custom Hoists - service items Procedure for adjusting headnuts on telescopic cylinders. A. For leaking cylinders: 1.Loosen set screw(s) in headnut of leaking stage(s). 2.Tap headnut lightly around circumference with a hammer. 3.Using a chain wrench, back headnut off one half to one full turn.
Page 61 Custom Hoists - service items Bleeding air from Single-Acting Telescopic Cylinders. 1.Empty the dump body of any material. 2.Remove the cover plate from the doghouse of the dump body to access the cylinder bleeder valve. 3.Fully extend the cylinder, raising the empty dump bed.
Page 62 Custom Hoists warranty Custom Hoists, Inc. warrants only products of its manufacture against operational failure caused by defective materials or workmanship which occur during proper and normal use within 24 months from the date of purchase from Custom Hoists, Inc. Custom Hoist, Inc. reserves the right to determine what is proper and normal use.
Page 63 Custom Hoists warranty shipped to Custom Hoists freight prepaid with the return authorization attached. In the event that a product is repaired under warranty, that product shall carry the remainder of the original warranty period. This limited warranty is in lieu of all other warranties of any nature, express or implied, including, but not limited to, warranties for merchantability or fitness or...
Page 64 Danger Do Not Climb on or Around Equipment While in Operation. Caution Don’t transport until unit is in the full safe travel position. Cargo is properly secured and PTO Disengaged...
Page 65 Hydraulic Oil Recommendations All internal cylinder parts are lubricated by hydraulic oil in the circuit. Particular attention must be paid to the condition and level of the oil in the circuit. Dirty oil is one of the main causes of hydraulic component failure resulting in expensive downtime.
Page 66 150 to 225 SSU @ 100°F (37.8°C) (Generally) 44 to 48 SSU @ 210°F (98.9°C) (Generally) • Approximate SSU at... Oil Grade 100° F 210° F (37.8° C) (98.9° C) SAE 10 SAE 20 Normal Temperature: 0°F (-18°C) to 100°F (37.8°C) Ambient 100°F (37.8°C) to 180°F (82.2°C) System Note: Where sustained temperatures exceed the above, use an oil suitable to the ambient temperature of your region.
Page 67 Truck-Lite - Preventative Maintenance Never use a test probe to pierce wire insulation when troubleshooting lighting complaints. Wicking action takes place, which causes moisture to travel along the wire strands and corrode critical connections. If probing a harness or wire is necessary, make sure the puncture is properly sealed.
Page 68 Truck-Lite - Preventative Maintenance On older trucks, you should never crank the truck when any lights or accessories are on. Also, never leave markers and hazard lights on when parked against a dock. Melted lenses are a sure sign that the vehicle has been parked against the dock while the lights were on.
Page 69 Maintenance Manual MM-0420 Trailer Axles with Unitized Wheel Ends Issued 05-04...
Page 70 Service Notes About This Manual ArvinMeritor’s Customer Service Center Call ArvinMeritor’s Customer Service Center at 800-535-5560. This manual provides wheel-end maintenance and service instructions for Meritor trailer axles with unitized wheel ends. Technical Electronic Library on CD Before You Begin The DriveTrain Plus™...
Page 71: Table Of Contents
Contents Asbestos and Non-Asbestos Fibers pg. i Section 1: Introduction Overview Scope Axle Identification Identification Tag Production Model Numbers Aftermarket Model Numbers Section 2: Unitized Wheel Ends Inspect the Unitized Wheel End Inspection Intervals Prepare the Trailer for Inspection Check for Smooth Rotation and Movement Check the Seals Check the Bearing End Play Section 3: TB Model...
Page 72 Asbestos and Non-Asbestos Fibers ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to asbestos ﬁber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos ﬁber dust, a cancer and lung disease hazard.
Page 73: Section 1: Introduction
1 Introduction Overview Refer to Maintenance Manual 14, Trailer Axles, for maintenance 1 Introduction information on the conventional wheel ends installed on all other Meritor offers two trailer axle models equipped with unitized Meritor trailer axle models to include TN, TP and TR Series axles. wheel ends.
Page 74: Production Model Numbers
1 Introduction The model number is composed of letters and digits; for example, TQD 4670 QH 2020 TB 4670 QH 2020. This number is used to identify the axle The second position indicates the type of bearings and spindle assembly when obtaining replacement parts. design used.
Page 75 1 Introduction TQD 4670 QH 2020 TQD 4670 QH 2020 The third position indicates whether the axle is a straight, drop or The fifth and sixth positions indicate the brake size. Figure 1.8. crank model. Figure 1.6. Figure 1.8 Figure 1.6 WIDTH STRAIGHT AXLE DIAMETER...
Page 76 1 Introduction TQD 4670 QH 2020 TQD 4670 QH 2020 The eighth position indicates whether the axle is built with cam, disc The final number group completes the trailer axle model number. or wedge brakes. Figure 1.10. Axle parameters described include, but are not limited to, the following items: axle track, Figure 1.12;...
Page 77 1 Introduction Figure 1.14 Figure 1.17 CAMSHAFT BUSHINGS STEEL SLEEVE CAMSHAFT PLASTIC LENGTH 4004285a CAM BUSHING 4004288a Figure 1.14 Figure 1.17 Figure 1.15 AIR CHAMBER AND SLACK PROVISIONS Figure 1.18 BRAKE CLOCKING 20˚ 20˚ 4004289a 4004286a Figure 1.18 Figure 1.15 Figure 1.19 SPIDER Figure 1.16...
Page 78 1 Introduction Figure 1.20 PRODUCTION AXLE MODEL NUMBERS Brake FMVSS121 Brake Diameter Design Variation Certification 2 = 12.25" (31 cm) C = Crank O = With certification 5 = 15" (38 cm) D = Drop 1 = With certification and ABS 6 = 16.5"...
Page 79: Aftermarket Model Numbers
1 Introduction Aftermarket Model Numbers Model numbers for Meritor aftermarket trailer axles are composed of letters and digits; for example, TQD 4670 QR 1120. When compared to the production numbering system, the aftermarket numbering system provides a more complete description of the axle. TQD 4670 QR 1120 The highlighted group above describes the same information as detailed previously for production model numbers.
Page 80 1 Introduction Figure 1.21 AFTERMARKET AXLE MODEL NUMBERS Brake Type Q Plus Cam Brake, Quick Change Less Brake Q Cam Brake, Quick Change P Cam Brake Brake Width Q with hub installed 1 = 10" (25 cm) = TRIAD bearing adjustment Brake Diameter 6 = 6"...
Page 81: Section 2: Unitized Wheel Ends
2 Unitized Wheel Ends Inspect the Unitized Wheel End ABS Warning Signal 2 Unitized Wheel Ends Inspect the wheel end for smooth rotation, movement and bearing Trailer axles built with unitized wheel ends provide extended end play if a driver reports that an ABS light has been coming on warranties and reduced maintenance requirements when compared and ABS diagnostics indicates excessive sensor gap.
Page 82: Check For Smooth Rotation And Movement
2 Unitized Wheel Ends Check for Smooth Rotation and Movement Place your hand on the brake air chamber that services the wheel end. Feel for any bearing vibration as the hub is rotated. You can perform the following inspections for smooth rotation and The air chamber will amplify any vibration.
Page 83: Check The Seals
2 Unitized Wheel Ends If the tires are not installed, push and pull on opposite sides of Figure 2.8 the hub flange and examine the wheel end for movement. TB MODEL Figure 2.6. Some grease If you detect movement: Check the bearing end play. may appear in this area.
Page 84: Check The Bearing End Play
2 Unitized Wheel Ends Figure 2.10 Figure 2.12 TB MODEL PUSH 4001743a Figure 2.12 4004039a Pull the hub OUTWARD until the dial indicator does not change. Do not rotate the wheel end. Figure 2.13. The difference in readings between pushing INWARD and pulling OUTWARD is Figure 2.10 the end play.
Page 85: Section 3: Tb Model
3 TB Model Description The retention hardware consists of a four-piece system including 3 TB Model two nuts, a bendable lock washer and a hardened washer. TB model trailer axles feature unitized hub assemblies fully Earlier versions of the retention hardware did not use a hardened assembled at the factory for simple installation and reduction of washed.
Page 86: Remove The Unitized Hub
3 TB Model Hazard Alert Messages Figure 3.5 HUBCAP Read and observe all Warning and Caution hazard alert messages in HUBCAP TO this publication. They provide information that can help prevent serious personal injury, damage to components, or both. WARNING "CAUTION REMOVAL OF LONG LIFE BEARINGS, SEALS OR LUBRICANT FROM MERITOR TB AXLE MODEL HUB WILL VOID...
Page 87 3 TB Model Remove the hubcap. Figure 3.11. WARNING Do not attempt to remove the tire and wheel, and hub and Figure 3.11 drum, as an assembly from the spindle. The clip inside the hub bore can dislodge, and the hub can disassemble. Serious personal injury and damage to components can result.
Page 88 3 TB Model Figure 3.13 Figure 3.15 4004960a 4001726a Figure 3.13 Figure 3.15 Remove the outer nut, lock washer, inner nut and inner washer, if provided. Early TB model axles did not use the inner washer. Figure 3.16 Figure 3.14. CLIP Take care when you remove the inner nut to prevent damage to the hub seal.
Page 89: Install The Unitized Hub
3 TB Model Install the Unitized Hub CAUTION Always use a metal plate at the end of the spindle when you WARNING use a puller to remove a hub to prevent damage to the spindle You must follow the installation procedures outlined below end plug.
Page 90 3 TB Model Figure 3.20 Figure 3.22 BACKUP COLLAR 4001731b Figure 3.22 4004296a Figure 3.23 Figure 3.20 Check the axle spindle and hub bore for scratches, nicks or marks. Repair them with a crocus or emery cloth. Figure 3.21. Figure 3.21 CROCUS 4004297a EMERY...
Page 91 3 TB Model Slide the O-ring onto the spindle. Figure 3.25. The O-ring If the hub assembly does not use a spindle O-ring: must be positioned so it rests at the corner radius of the Apply a light coating of bearing grease to the axle spindle backup collar.
Page 92 3 TB Model WARNING Figure 3.29 The hub must be rotated while the spindle nut is tightened to the correct torque specification. The nut can loosen if it is not Grease will tightened correctly. The bearings may not seat correctly if the appear here.
Page 93 3 TB Model 14. Install the brake drum and the tire and wheel assembly. Figure 3.33 Figure 3.36. Figure 3.36 TABS 4001723a Figure 3.33 4004958a 12. Lightly lubricate the hubcap O-ring and the hubcap threads with bearing grease. Figure 3.34. Figure 3.36 Figure 3.34 15.
Page 94: Section 4: Tl Model
4 TL Model Description The inboard side of the hub contains a secondary seal designed 4 TL Model to protect the primary inboard seal. Figure 4.4. TL model trailer axles feature unitized hub assemblies fully The non-serviceable bearing cartridge is held in place by a assembled at the factory for simple installation and reduction of heavy-duty snap ring visible from the outboard side of the hub.
Page 95 4 TL Model Figure 4.4 Figure 4.7 PRIMARY INBOARD SECONDARY SEAL SEAL 4004301a Figure 4.4 4004303a Figure 4.5 SNAP Figure 4.7 RING Figure 4.8 RETAINING SPINDLE WASHER 4004299a 4004304a Figure 4.5 Figure 4.8 Figure 4.6 Hazard Alert Messages Read and observe all Warning and Caution hazard alert messages in this publication.
Page 96: Remove The Unitized Hub
4 TL Model Remove the Unitized Hub WARNING Do not attempt to remove the tire and wheel, and hub and Under normal operating conditions, you are not required to remove drum, as an assembly from the spindle. The clip inside the hub the TL model unitized hubs from the axle spindle.
Page 97 4 TL Model Remove the hubcap and hubcap gasket. Figure 4.12. Figure 4.14 Figure 4.12 4004310a Figure 4.14 4004305a CAUTION Always use a metal plate at the end of the spindle when you Figure 4.12 use a puller to remove a hub to prevent damage to the spindle end plug.
Page 98: Install The Unitized Hub
4 TL Model 10. Remove the secondary oil seal from the hub. When you remove WARNING the secondary seal, you must protect the interior of the unitized When you remove the hub from the axle spindle, carefully pull hub with a plate. Figure 4.18. the hub off the spindle as straight as possible to help avoid dislodging the clip inside the hub bore.
Page 99 4 TL Model CAUTION Figure 4.19 Remove all debris from the joint between the hub and axle backup collar. If debris is trapped in this joint, it could create a condition in which clamp on the hub is lost resulting in damage to components.
Page 100 4 TL Model Install a new secondary seal into the hub. Figure 4.24. WARNING Install the seal on the correct driver with the “oil side” You must align the hub bore straight to the axle spindle to mark facing the interior of the hub. help avoid dislodging the clip inside the hub bore.
Page 101 4 TL Model 10. Check the hub to verify that it rotates freely. Figure 4.27 If the hub assembly does not rotate freely: Perform the hub inspection procedures in Section 2 of this manual. RETAINING WASHER 11. Stake a previously unused section of the outer flange of the retaining washer into only ONE of the slots on the face of the nut flange.
Page 102 4 TL Model 12. Install the hubcap by tightening the capscrews to 10-15 lb-ft Figure 4.31 CORRECT STAKING (13-20 N m) in a crisscross pattern. Use a new hubcap gasket. Figure 4.34. Figure 4.34 4004318a Figure 4.31 Figure 4.32 INCORRECT STAKING 4004305a Figure 4.34 13.
Page 103: Section 5: Component Service
5 Component Service Hazard Alert Messages Brakes 5 Component Service Read and observe all Warning and Caution hazard alert messages in Service Brakes Without Removing Hubs this publication. They provide information that can help prevent Trailer axles equipped with unitized wheel-end systems and cam serious personal injury, damage to components, or both.
Page 104 5 Component Service Use a screwdriver to pry the bolt-on bushing out of the spider retainer hole. The bushing has recesses to help you remove it. Figure 5.4. Figure 5.4 SCREWDRIVER BOLT-ON BUSHING 4001740a Figure 5.4 Move the camshaft head AWAY from the axle, so that the camshaft head clears the hub flange.
Page 105 Meritor Heavy Vehicle Systems, LLC 2135 West Maple Road Printed in USA Troy, MI 48084 USA 800-535-5560 Copyright 2004 Issued 05-04 arvinmeritor.com ArvinMeritor, Inc. Maintenance Manual MM-0420 (16579/24240)
Page 106 Maintenance Manual 14 Trailer Axles Revised 03-07...
Page 107 Service Notes About This Manual ArvinMeritor’s Customer Service Center Call ArvinMeritor’s Customer Service Center at 800-535-5560. This manual provides maintenance and service information for Meritor trailer axles. Technical Electronic Library DVD Before You Begin The DriveTrain Plus™ by ArvinMeritor Technical Electronic Library DVD contains product and service information for most Meritor and Read and understand all instructions and procedures before Meritor WABCO products.
Page 108 Contents Asbestos and Non-Asbestos Fibers Section 7: Welding Guidelines Section 1: Exploded View Only Use Certified Welders Typical 16.5″ x 7″ Q Series Brake Installation Methods Section 2: Introduction Axle Preparation Important Information Hardware Fit Description Welding Preparation Axle Models Location About This Manual Welding Procedures...
Page 109 Contents Section 12: Cam Brakes pg. 63 Important Information Cam Brakes Components Trailer Axles with Cam Brakes Spiders Cam Bushings Camshafts Air Chamber Brackets Important Information Air Chambers and Slack Adjusters Q Series and Q Plus™ Brakes Cam Bushings Bolt-On Bushing Replacement Replacing the Cam Without Removing the Hub Replacing the Weld-On Retainer Upgrading the Bushing on the Spider End of the Cam...
Page 110 Asbestos and Non-Asbestos Fibers Figure 0.1 ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to asbestos ﬁber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos ﬁber dust, a cancer and lung disease hazard.
Page 111: Section 1: Exploded View
1 Exploded View Typical 16.5″ x 7″ Q Series Brake Installation 1 Exploded View Figure 1.1 LEFT RIGHT 4003153a...
Page 112 1 Exploded View Item Description Item Description Capscrew Brake Shoe and Lining Assembly Lock Washer Brake Shoe Retaining Spring Hubcap Brake Shoe Roller Retainer Gasket Brake Shoe Roller Wheel Bearing Jam Nut Shoe Return Spring Pin Lock Washer Dust Shield Set Screw Wheel Bearing Adjusting Nut Outer Wheel Bearing Cone...
Page 113: Section 2: Introduction
2 Introduction Important Information Axle Designs 2 Introduction Meritor trailer axles are available in the following designs. Meritor automatic slack adjusters (ASAs) should not need to be manually adjusted in service. ASAs should not have to be adjusted Beam Designs to correct excessive pushrod stroke.
Page 114: Identification
2 Introduction Beam Cross Sections The serial number is composed of letters and digits; for example, KNA-38050685. This number can be used to identify a particular Round trailer axle, and the material and components used to build the axle. Rectangular, available only as service replacement beams The date of manufacture is indicated by a Julian date;...
Page 115 2 Introduction Figure 2.5 CURRENT PRODUCTION MODEL NUMBERS ➀ Brake Diameter Design Variation FMVSS121 Brake Certification 2 = 12.25" (31 cm) C = Crank ➁ O = With certification 5 = 15" (38 cm) D = Drop 1 = With certification and ABS 6 = 16.5"...
Page 116: Section 3: Removal And Disassembly
3 Removal and Disassembly Important Information 3 Removal and Disassembly Figure 3.1 Meritor automatic slack adjusters (ASAs) should not need to be manually adjusted in service. ASAs should not have to be adjusted to correct excessive pushrod stroke. The excessive stroke may be an indication that a problem exists with the foundation brake, ASA, brake actuator or other system components.
Page 117 3 Removal and Disassembly CAUTION Figure 3.3 You must disengage a pull pawl or remove a conventional pawl before rotating the manual adjusting nut, or you will damage the pawl teeth. A damaged pawl will not allow the slack adjuster to automatically adjust brake clearance. Replace damaged pawls before putting the vehicle in service.
Page 118 3 Removal and Disassembly Figure 3.6 CAPSCREW 4003164a Figure 3.6 WARNING Do not loosen the axle spindle nuts by either striking them directly with a hammer, or striking a drift or chisel placed against them. Damage to the parts will occur causing possible loss of axle wheel-end components and serious personal injury.
Page 119 3 Removal and Disassembly CAUTION Figure 3.9 Be careful when you remove the hub and drum assembly that you do not damage the outer bearing by dropping it on the floor. 10. Remove the outer bearing cone, then the hub and drum assembly from the axle spindle.
Page 120: Brakes
3 Removal and Disassembly Brakes Figure 3.12 RETURN SPRING ASBESTOS AND NON-ASBESTOS FIBERS WARNING Some brake linings contain asbestos fibers, a cancer and lung disease hazard. Some brake linings contain non-asbestos fibers, whose long-term effects to health are unknown. You must use caution when you handle both asbestos and non-asbestos materials.
Page 121 3 Removal and Disassembly Disengage the slack adjuster from the air chamber push rod by Figure 3.14 removing the two slack adjuster clevis pins. Discard the two cotter pins that secure the clevis pins. CAUTION You must disengage a pull pawl or remove a conventional pawl before rotating the manual adjusting nut, or you will damage the pawl teeth.
Page 122: Section 4: Clean And Inspect Parts
4 Clean and Inspect Parts Hazard Alert Messages Clean Smooth Parts 4 Clean and Inspect Parts Read and observe all Warning and Caution hazard alert messages in CAUTION this publication. They provide information that can help prevent Do not use hot solution tanks or water and alkaline solutions to serious personal injury, damage to components, or both.
Page 123: Prevent Corrosion
4 Clean and Inspect Parts Prevent Corrosion If a crack is found in a weld attaching any component to the axle, and if this crack extends into the axle tube: If parts are to be immediately assembled, apply lubricant to all Replace the axle.
Page 124 4 Clean and Inspect Parts 10. Inspect the brake equipment. Repair or replace damaged Figure 4.4 components. Refer to the Service Notes page on the front AXIAL inside cover of this manual for instructions on how to obtain the PLAY correct Meritor maintenance manual for the brake you are servicing.
Page 125 4 Clean and Inspect Parts The rib is worn. Figure 4.6. Figure 4.9 Figure 4.6 4003182a Figure 4.9 4003179a Figure 4.10 Figure 4.6 C. The roller cage is damaged. Figure 4.7 and Figure 4.8. Figure 4.7 4003180a Figure 4.7 Figure 4.8 4003183a Figure 4.10 The bearing is discolored.
Page 126 4 Clean and Inspect Parts The cage, cup, cone or rollers are grooved. Figure 4.12. H. The races or rollers are etched. Figure 4.14. Figure 4.12 Figure 4.14 CAGE CONE ROLLERS 4003185a 4003187a Figure 4.12 Figure 4.14 G. The races or rollers are bruised with deep indentations. The races or rollers are spalled.
Page 127 4 Clean and Inspect Parts Figure 4.18 Figure 4.16 4003191a Figure 4.18 4003189a Figure 4.16 The races or rollers are brinelled. Figure 4.19. The races or rollers are gouged or nicked. Figure 4.17 Figure 4.19 and Figure 4.18. Figure 4.17 4003192a Figure 4.19 The races or rollers are cracked.
Page 128: Section 5: Assembly And Installation
5 Assembly and Installation Important Information Installation 5 Assembly and Installation Meritor automatic slack adjusters (ASAs) should not need to be Brakes manually adjusted in service. ASAs should not have to be adjusted to correct excessive pushrod stroke. The excessive stroke may be Most Meritor trailer axles are equipped with Q Series cam brakes.
Page 129 5 Assembly and Installation Figure 5.2 Figure 5.3 RETAINING SPRING MANUAL ADJUSTING Refer to the handed and unhanded illustrations at the beginning of this ANCHOR PIN procedure for possible pawl locations. 4003172a 4003195a Figure 5.2 Figure 5.3 CAUTION NOTE: You can remove a standard return spring by hand, if one is Always replace used clevis pin retainer clips with new ones installed.
Page 130: Wheel Ends
5 Assembly and Installation Lubricate the cam rollers with grease where they touch the 10. Lubricate the camshaft bushings and slack adjusters as brake shoe webs, making sure not to get lubricant on the outer follows. diameter of the roller that touches the camshaft head. Wipe off the grease fittings to prevent contamination from Pull each brake shoe away from the cam permitting enough being injected into the joints along with grease.
Page 131 5 Assembly and Installation WARNING Figure 5.9 SPINDLE-MOUNTED SEAL Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. Install the seal and inner bearing cone.
Page 132 5 Assembly and Installation Figure 5.11 Figure 5.12 4003165a Figure 5.11 4003203a CAUTION Figure 5.12 When you tighten the spindle nuts, the hub and drum assembly will seat to the correct position. Do not try to Adjust the bearings as specified in Section 10. completely seat the hub and drum assembly by hand.
Page 133 5 Assembly and Installation CAUTION Add wheel-end lubricant only to the hubcap fill line. Do not overfill the hubcap. Wipe off excess lubricant, which can contaminate brake linings and cause reduced brake performance. Damage to components can result. Fill the wheel end with oil to the hubcap fill line. Note that the oil must be given sufficient time to settle prior to the final check of the oil level.
Page 134: Section 6: Additional Installation Information
6 Additional Installation Information Hazard Alert Messages Axle Positioning 6 Additional Installation Information Read and observe all Warning and Caution hazard alert messages in CAUTION this publication. They provide information that can help prevent Follow these instructions to correctly position an axle. An axle serious personal injury, damage to components, or both.
Page 135: Important Information
6 Additional Installation Information Axle Top and Bottom Axle Front and Rear Most Meritor trailer axles are built with a 0.31-inch The front and rear of the axle can be identified using the location of (7.874 mm) diameter hole partially drilled through the axle the ID tag or embossing along with information regarding the correct tube.
Page 136: Brake Installation
6 Additional Installation Information Brake Installation Trailer axles built with cam brakes should be installed so that the camshaft rotates in the same direction as the tires when the vehicle is moving forward. Figure 6.5. Trailer axles built with wedge brakes must be installed so that the tires rotate in the direction indicated on the brake shoe webs.
Page 137 6 Additional Installation Information Figure 6.7 Figure 6.8 TOP-CENTER HOLE 20˚ 20˚ TOP-CENTER TOP-CENTER HOLE HOLE VERTICAL 4003209a CENTERLINE Figure 6.7 Non-cambered axles may be built either with or without a top-center VERTICAL 4003210a CENTERLINE hole. These models must be installed as follows: On models with a top-center hole: The top-center hole must Figure 6.8 be located within 20 degrees of vertical and the brake hardware...
Page 138: Suspension
6 Additional Installation Information Figure 6.10 Figure 6.12 DISC BRAKES WEDGE BRAKES 20˚ 20˚ HORIZONTAL HORIZONTAL AIR CHAMBER CENTERLINE CENTERLINE POWER SCREW SUPPORT BRACKET 4003212a Figure 6.10 4003214a Figure 6.12 Wedge brakes with air chamber tube support brackets: When wedge brakes are equipped with air chamber support Suspension brackets, the centerline of the brackets must be located within 20 degrees of the axle horizontal centerline.
Page 139: Dust Shields
6 Additional Installation Information On the mounting set-up shown in Figure 6.14, a suspension bracket Figure 6.15 DECREASED LOAD does not isolate the bottom of the axle from compression forces FIFTH WHEEL ON FRONT AXLE exerted by tightening the U-bolts. This isolation must be obtained by TOO HIGH installing plates, at least 0.25-inch (6.3 mm) thick, between the axle and the U-bolts.
Page 140: Spindle Protection
6 Additional Installation Information Dust shields are mounted to stamped spiders with four fasteners. Dust shields are mounted to a separate welded-on bracket on axles Figure 6.17. built with 12-1/4 x 7-1/2-inch brakes. Refer to Figure 6.19 and Section 7 for detailed instructions on locating and welding this bracket to the trailer axle.
Page 141: Unit-Mounted Brakes
6 Additional Installation Information Plastic Sleeve Remove moisture or contamination found on the spindle with a clean rag. The most common method is to fit a plastic sleeve over the spindle. Coat the axle spindle with axle lubricant as specified in CAUTION Section 5.
Page 142 6 Additional Installation Information Unit-mounted brakes, standard on drive axles, are then mounted to For a 12-hole flange: Fasten the brake by installing the correct the trailer axle by bolting the brake spider to this flange. 9/16-inch (14.288 mm) diameter fasteners through the 11 Figure 6.23.
Page 143: Guidelines
7 Welding Hazard Alert Messages 7 Welding Method for Welding Carbon AWS Electrode and Low Alloy Steels Classification Specification Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent Shielded Metal Arc E70XX A5.1 serious personal injury, damage to components, or both.
Page 144: Hardware Fit
7 Welding Hardware Fit Brackets on rectangular axles should fit the axle so that the point of contact is at the tangent point of the axle radius. Figure 7.3. Hardware at the weld site should fit as close as possible to the axle.
Page 145: Location
7 Welding Figure 7.5 Figure 7.7 Do not place tack welds at the ends of the bracket. 4003234a DAMAGED BEARING ROLLER AND RACE Figure 7.7 4003232a Location Figure 7.5 Axles are more likely to crack at a weld location, since welds lower Prior to applying final welds, hardware should be tack welded to the strength of the axle material adjacent to the weld and set up a the axle following recommendations provided by the component...
Page 146 7 Welding Figure 7.9 Figure 7.11 1.50" 1.50" VERTICAL WELD AXLE TOP Measured CENTER on the axle surface. 1.50" VERTICAL WELD AXLE HORIZONTAL 1.0" VERTICAL WELDS 4003236a CENTERLINE PERMITTED IN THIS AREA — Figure 7.9 BOTH SIDES 4003238a Horizontal welding is not allowed more than 1.50-inches Figure 7.11 (38.1 mm) below the axle horizontal centerline.
Page 147 7 Welding Figure 7.14 Figure 7.12 VERTICAL WELD 1" 1.0" 1" AXLE CENTER VERTICAL WELD 1.0" AXLE HORIZONTAL VERTICAL WELDS CENTERLINE PERMITTED IN THIS AREA — BOTH SIDES 4003239a 4003241a Figure 7.12 Figure 7.14 Horizontal welding is not allowed more than 1.50-inches Weld location requirements in this section apply to all welds.
Page 148: Welding Procedures
7 Welding Welding Procedures Figure 7.17 CURBSIDE Observe the following when performing welding procedures. CURBSIDE REAR FRONT Axles are more likely to crack at the end of the bracket attachment welds. It is critical to avoid welding imperfections ROADSIDE such as craters, undercuts and poor fusion at these locations. FRONT Some methods of avoiding these imperfections include using correct welding parameters, starting and stopping the arc a short...
Page 149: Section 8: Alignment
8 Alignment Hazard Alert Messages — Incorrect tire inflation pressure. 8 Alignment — The rolling radii of a set of dual tires on a wheel end not Read and observe all Warning and Caution hazard alert messages in matching within 0.125-inch (3.1 mm). Figure 8.2. this publication.
Page 150 8 Alignment Figure 8.3 Figure 8.4 PARALLEL TRAILER AXLES FRONT AXLE POSITIONED RELATIVE REAR AXLE TO VEHICLE POSITIONED RELATIVE TO FRONT AXLE 4003248a 4003247a Figure 8.4 Figure 8.3 Kingpin extenders are designed to ease axle orientation by allowing the measuring device used to orient the front trailer axle to clear Before performing an axle orientation, the vehicle suspension must obstructions under the trailer.
Page 151: Single-Axle Trailers
8 Alignment Figure 8.6 Figure 8.7 TRAMMEL BAR 4003250a 4003251a Figure 8.6 Figure 8.7 Single-Axle Trailers Figure 8.8 Prepare the suspension by positioning the trailer on a level floor and moving it forward and backward several times in a straight KINGPIN line.
Page 152: Double Or Triple Trailers
8 Alignment Double or Triple Trailers Figure 8.9 In most cases, the previous two procedures can be used to orient axles on double or triple trailers. However, if these procedures are used and problems with tire wear or tracking persist, use the following procedure to orient axles to the pull line of the trailer.
Page 153: Converter Dollies
8 Alignment Lower the dolly onto the supports. Figure 8.12 Hang plumb lines from the exact centers of the lunette eye and fifth wheel where it holds the trailer kingpin. Establish the pull PINTLE line by marking these points on the floor and snapping a chalk HOOK line through them.
Page 154: Axle Camber
8 Alignment Hang plumb lines from the exact centers of the roadside and Meritor builds both cambered and non-cambered trailer axles. curbside front axle spindles. Establish the axle location by — Camber is currently available on crank axles and straight marking these points on the floor and snapping a chalk line axles with round cross sections.
Page 155: Axle Camber Measurement
8 Alignment When a commercial alignment machine is used to measure the Figure 8.16 camber of a trailer axle assembly installed onto a vehicle, the measurement obtained is vehicle camber. Vehicle camber INNER BEARING TOP OF includes the camber of the bare axle beam, as well as the effect JOURNAL AXLE on camber of the following.
Page 156: Axle Toe
8 Alignment Table B: Axle Camber Figure 8.17 AXLE TOE, Dial Indicator Axle Camber SHOWN EXAGGERATED Reading (Inches) (Minutes) VEHICLE 0.0000 CENTERLINE 0.0145 STRAIGHT KINGPIN AHEAD 0.0291 0.0436 0.0582 ANGLE 0.0727 0.0873 0.1018 0.1163 0.1309 0.1454 0.1600 0.1745 4003261a Check the camber on the opposite end of the axle using the Figure 8.17 same procedure.
Page 157 8 Alignment Toe specifications detailed in Table C are for axles prior to Excessive axle toe is generally due to a spindle bent from a tire welding on suspension brackets. Note the following in regard to impact. The wheel position shown to sustain the most impacts is bracket welding.
Page 158: Axle Toe Measurement
8 Alignment Axle Toe Measurement Table D: Axle Toe Dial Indicator Reading (Inches) Axle Toe (Minutes) Prepare the axle as outlined in Step 1 through Step 5 of the axle camber measurement procedure in this section. 0.0000 At the front of the axle, measure exactly five-inches (127 mm) 0.0058 from the line on the inner bearing journal to the outer bearing 0.0116...
Page 159: Section 9: Conventional Wheel-End Equipment
9 Conventional Wheel-End Equipment Hazard Alert Messages 9 Conventional Wheel-End Equipment Figure 9.2 AXLE Read and observe all Warning and Caution hazard alert messages in SPINDLE this publication. They provide information that can help prevent serious personal injury, damage to components, or both. WARNING To prevent serious eye injury, always wear safe eye protection when you perform maintenance or service.
Page 160: Meritor Axles
9 Conventional Wheel-End Equipment Meritor Axles On positive adjust axles, the inner nut of the wheel retention hardware does not have an alignment pin and is marked as To determine whether a particular axle uses the manual or positive shown. Figure 9.5. bearing adjustment method, refer to the Model Numbers chart in Section 2 as well as the following guidance.
Page 161: Wp Axles
9 Conventional Wheel-End Equipment Figure 9.7 Figure 9.8 ADJUSTMENT HOLES SPINDLE THREAD DIAMETER Spindle Thread Diameter (Inches) Axle Model Manual Positive TN, TQ, RN, RQ, TKN 2-5/8 2-3/8 3-1/2* 3-1/4 4003271a TR, TT 3-1/4 Not Available Figure 9.8 2-5/8 Not Available 4003270a Note that the wheel-end configuration for this model was designed, Figure 9.7...
Page 162: Hubs And Spoke Wheels
9 Conventional Wheel-End Equipment Table E: Trailer Axle Bearings Inner Outer Adjustment Axle Series Method Cone Cone TN/TQ/TKN Manual HM218210 HM218248 HM212011 HM212049 TN/TQ/TKN Positive 1228-P-406 1228-Q-407 1228-M-403 1228-N-404 RN/RQ Manual HM218210 HM218248 HM212011 HM212049 RN/RQ Positive 1228-P-406 1228-Q-407 1228-M-403 1228-N-404 Manual HM518410...
Page 163: Disc Wheel Equipment
9 Conventional Wheel-End Equipment Figure 9.11 Figure 9.12 TIRES, RIMS DISC WHEEL SYSTEM TIRE AND NUTS AND AND SPACER WHEEL SPOKE WHEEL SYSTEM CLAMPS ASSEMBLY AXLE AXLE WHEEL BRAKE DRUM SPOKE WHEEL BRAKE DRUM STUD ASSEMBLY 4003274a 4003273a Figure 9.11 Figure 9.12 Positive bearing adjustment is only available on trailer axles fitted Brake drums used on disc wheel equipment may be mounted either...
Page 164 9 Conventional Wheel-End Equipment On outboard-mounted drums: With this configuration, the Do not mix hub-piloted and stud-piloted wheel-end brake drum is mounted outboard of the hub flange. Therefore, equipment. Mixing this equipment can result in damage to the hub can remain in place when removing the brake drum. The the wheel end and serious personal injury.
Page 165: Spoke Wheel Equipment
9 Conventional Wheel-End Equipment Hub Pilot Figure 9.18 With this method, the tire-wheel assembly is centered on the hub by SPOKE WHEEL SYSTEM piloting the wheel over a pilot diameter machined into the hub. Only TIRES a single nut is required at each stud location regardless of whether NUTS AND AND RIMS CLAMPS...
Page 166 10 Manual Bearing Adjustment Hazard Alert Messages To help ensure that a correct bearing adjustment can be 10 Manual Bearing Adjustment achieved, be sure to do the following prior to performing this Read and observe the Warning and Caution hazard alert messages adjustment: in this publication.
Page 167: Section 10: Manual Bearing Adjustment
10 Manual Bearing Adjustment A set screw was not used on an earlier manual adjust TP axle Figure 10.3 model. A bendable tab lock washer, rather than a set screw, is used on the current production TR axle model. Use the following procedure to adjust the wheel bearings. Install the adjusting nut so that the pin on the nut faces away from the wheel-end equipment.
Page 168 10 Manual Bearing Adjustment Slightly rotate the wheel end in both directions while Figure 10.6 pushing inward until the dial indicator does not change. PIN AND PIN AND Set the dial indicator to ZERO. Figure 10.8. HOLE HOLE NOT ALIGNED ALIGNED Figure 10.8 Turn lock washer...
Page 169: Single Nut Adjustment Procedure
10 Manual Bearing Adjustment D. End play is the difference between the two readings. Figure 10.11 WARNING You must adjust wheel bearing end play to within 0.001-0.005-inch (0.025-0.127 mm). An adjustment that is too loose will reduce wheel-end bearing life, increase spindle wear and cause seal leakage.
Page 170: Single-To-Double Nut Conversion
10 Manual Bearing Adjustment Use the following procedure to adjust the wheel bearings. WARNING Install the washer and castellated nut. Tighten the nut to You must adjust wheel bearing end play to within 200 lb-ft (271 N m) while rotating the wheel end in both 0.001-0.005-inch (0.025-0.127 mm).
Page 171 11 Positive Bearing Adjustment Hazard Alert Messages If the correct end play is not achieved after following this 11 Positive Bearing Adjustment procedure, the axle must either be converted to a manual Read and observe the Warning and Caution hazard alert messages adjust system or new close tolerance hubs and bearings must in this publication.
Page 172: Section 11: Positive Bearing Adjustment
11 Positive Bearing Adjustment WARNING Figure 11.3 QUICK REFERENCE You must adjust wheel bearing end play to within a ADJUSTING NUT 0.001-0.005 inch (0.025-0.127 mm) specification. An INSTALLATION adjustment that is too loose will reduce wheel-end bearing Tighten nut life, increase spindle wear and cause seal leakage. An to 250-300 lb-ft adjustment that is too tight can affect wheel-end bearing (340-408 N•m).
Page 173 11 Positive Bearing Adjustment On TP axle model where the innermost component is a washer, replace with part number 1229-B-3122 and the adjusting nut with part number 1227-W-517. Figure 11.6. Figure 11.6 RECESSED RECESSED FACE FACE CONVERSION WASHER 1229-B-3122 4003301a Figure 11.6 After changing this equipment, adjust the bearings using the manual adjustment method detailed in the procedure for...
Page 174 12 Cam Brakes Important Information Cam Brakes 12 Cam Brakes Meritor automatic slack adjusters (ASAs) should not need to be Repair kits are available from Meritor Aftermarket Services and can manually adjusted in service. ASAs should not have to be adjusted be found in Meritor’s Parts Book PB-8857, Brake, Trailer and Wheel to correct excessive pushrod stroke.
Page 175 12 Cam Brakes Spiders Figure 12.4 STAMPED SPIDER Brake spiders are welded to the axle just inboard of the spindle. Three models may be encountered. A forged spider model is currently used when a brake rating must exceed 23,000 pounds (8585 kg). Figure 12.2. Figure 12.2 FORGED SPIDER WITHOUT...
Page 176 12 Cam Brakes Cam Bushings Figure 12.8 Cam bushings are installed at the spider and slack adjuster ends of the cam. Three bushings may be encountered at the spider. A plastic sleeve bushing can be installed onto all three spider models.
Page 177 12 Cam Brakes An arrangement used in the past consists of a bushing with a Figure 12.11 90-degree grease fitting installed onto a camshaft bracket with a round hole. When assembled, the grease fitting is oriented JOURNAL “A” toward the slack adjuster. Figure 12.10. (inches) Non-heat- Figure 12.10...
Page 178 12 Cam Brakes Figure 12.13 Figure 12.15 “V-TYPE” AIR 2.075" CHAMBER BRACKET BUSHING JOURNAL SPIDER 4003316a Figure 12.15 SPACE WASHER 4003314a There are old and new versions of the “V-Type” bracket. Both make provisions for the use of three different slack lengths as stamped Figure 12.13 into the bracket.
Page 179 12 Cam Brakes Figure 12.17 Figure 12.18 “CHANNEL-TYPE” AIR CHAMBER BRACKET 105˚ ± 1˚ 4003318a 4003319a Figure 12.17 Figure 12.18 Important Information CAUTION Five different installation templates are available from Meritor. Meritor automatic slack adjusters (ASAs) should not need to be These templates are designed to be used with specific model manually adjusted in service.
Page 180 12 Cam Brakes Table G: Push Rod Length Figure 12.20 Install both Push Rod clevis pins. Brake Chamber Length Axle Model Model Bracket (Inches) TN, TQ, TP, 16.5 “V Type” 5.75 TR, TKN, TK, TN, TQ, TP, 16.5 “Channel 4.25 CAMSHAFT TR, TKN, Type”...
Page 181 12 Cam Brakes The equipment required for Q Series and Q Plus™ brakes is Figure 12.23 detailed below and shown in Table H. MINIMUM 0.5" Camshafts — Q Series brakes can use either Q Series or Q Plus™ camshafts. Q Plus™ brakes must use Q Plus™ camshafts in order to accommodate the greater shoe travel as the thicker linings wear.
Page 182 12 Cam Brakes Q Series and Q Plus™ brake equipment can be identified as follows. Figure 12.25. Figure 12.25 Q SERIES Q PLUS PLUS SHAPED (+) HOLES THROUGH TABLE ON BOTH SIDES OF WEB MERITOR BULGE ON MERITOR NO BULGE 16.5 Q 16.5 Q PLUS™...
Page 183 12 Cam Brakes Cam Sleeve Bushings at the Spider End Figure 12.28 Remove the snap ring, then pull the camshaft from the axle. Remove all loose parts from the camshaft and retainer bore including the grease seals and washers. Figure 12.27. RETAINER BORE Figure 12.27...
Page 184 12 Cam Brakes For metal bushings, install two grease seals. Verify that Figure 12.30 the seal lips face toward the slack adjuster and that the seal bodies press against the metal bushing. SPIDER METAL Figure 12.32. BUSHING CENTERED IN RETAINER Figure 12.32 TIRE 0.29"...
Page 185 12 Cam Brakes Install the following equipment onto the camshaft and then Figure 12.34 install the camshaft through the second bushing. For plastic bushings, install the washer onto the camshaft. For metal bushings, install the washer and spacer onto the camshaft. Install the snap ring.
Page 186 12 Cam Brakes Remove the snap ring at the inboard side of the bushing and Figure 12.36 TIRE the four capscrews from the bushing. Figure 12.38. SLACK ADJUSTER Figure 12.38 BOLT-ON BUSHING ASSEMBLY CAPSCREWS, FOUR Camshaft shown installed for reference only. SNAP RING 4003338a 4003333a...
Page 187 12 Cam Brakes Replacing the Weld-On Retainer Figure 12.40 If the weld-on retainer used on the stamped spiders is either damaged or worn, it can be replaced. Figure 12.42. Figure 12.42 4003340a 4003342a RETAINER Figure 12.40 Figure 12.42 Install the new bolt-on bushing and cam by reversing the procedure.
Page 188 12 Cam Brakes Press the old retainer out of the spider with a C-clamp. Weld the retainer in four places using AWS E70S3 or E70S6 electrodes. Each weld should have a 0.1875-inch (4.76 mm) Press a new retainer into the spider with a C-clamp. fillet and be 0.375-inch (9.52 mm) long.
Page 189 13 Anti-Lock Braking System Hazard Alert Messages This wheel speed monitoring equipment consists of the following 13 Anti-Lock Braking System components. Read and observe all Warning and Caution hazard alert messages in Tooth Wheel — A 100 tooth wheel mounted to the hub or spoke this publication.
Page 190 13 Anti-Lock Braking System Sensor Block — Welded to the axle between the spider and oil Figure 13.6 seal collar, the sensor block holds the sensor in correct position relative to the tooth wheel. Figure 13.4. SENSOR BLOCK TOP OF AXLE Figure 13.4 SENSOR BLOCK NINE O’CLOCK...
Page 191 13 Anti-Lock Braking System The least common position is near six o’clock. A sensor can end up You can make a special tool to reach the back of the sensor through in this area when an ABS-equipped axle is rotated 180 degrees the brake equipment.
Page 192 13 Anti-Lock Braking System Route the ABS wires on TP and TR model axles equipped with Figure 13.11 cam brakes without an ABS spider hole as follows. PASS WIRE THROUGH SPIDER HOLE Figure 13.13. Figure 13.13 SHOULD VIEW OF AXLE AGAINST SPIDER SENSOR...
Page 193 13 Anti-Lock Braking System Route the ABS wires on axles equipped with disc brakes as Meritor current production two-piece dust shields are designed follows. The sensor must be completely clear of the spinning to be used either with or without ABS equipment. Each dust disc brake rotor, otherwise it will be damaged.
Page 194 13 Anti-Lock Braking System Currently brake flanges are available with nine, 12 and 16 hole patterns. For all three designs, the ABS wire should pass through the 0.8125-inch diameter hole and the remaining holes should be used for fastening the brake spider as detailed in Section 6.
Page 195 14 Lubrication Hazard Alert Messages Cam Brakes 14 Lubrication The following provides information on lubricating Meritor cam brake Read and observe all Warning and Caution hazard alert messages in components installed onto trailer axles. this publication. They provide information that can help prevent serious personal injury, damage to components, or both.
Page 196 14 Lubrication Slack Adjuster Clevis Pins Approved Lubricants, Intervals and Specifications Lubricate the entire pin. Table I: Approved Lubricants Lubricate when the brake is disassembled or as necessary. Lubricant Specification Recommendation Camshaft Bushings O-616-A Shell Darina Grease 1 Apply the specified grease at the grease fitting on the spider. Apply Texaco Thermatex EP-1 grease until new grease purges from all the seals.
Page 197 14 Lubrication Table J: Cam Brake Grease Specifications Meritor Outside Components Specification NLGI Grade Grease Type Temperature Down to −40°F Retainer Clips Anchor Pins Roller, Journals O-616-A Clay Base Only, Camshaft Bushings (−40°C) When the brake is disassembled, or when O-617-A or Lithium Refer to the grease...
Page 198 14 Lubrication Wheel-End Maintenance Guidelines Service environment, mileage, speed and axle load are some factors This section provides information on lubricating Meritor trailer axle that determine how often you should change wheel-end lubricant. wheel ends with either grease or oil. Figure 14.2. For example, a heavy-service application, such as an off-highway dump trailer, stresses the lubricant, and requires you to perform Figure 14.2...
Page 199 14 Lubrication Grease-Lubricated Wheel Ends CAUTION It is important not to overfill the wheel-end cavity with The most common greases used in Meritor trailer axle wheel ends have a designation of NLGI (National Lubricating Grease Institute) lubricant. Wheel-end oil level should never exceed the middle of the hubcap.
Page 200 14 Lubrication WARNING Figure 14.6 Do not use gasoline to clean parts. Gasoline can explode or burn and cause serious personal injury. To remove grease from a wheel end, use a stiff fiber brush, not steel, and kerosene or diesel fuel oil, not gasoline. Allow clean parts to dry, then wipe them with a clean, absorbent cloth.
Page 201 14 Lubrication Figure 14.7 Shading indicates correct amount of grease. 4003369a Figure 14.7 Install the hub onto the spindle without the outer bearing cone in place. CAUTION When you lubricate the wheel-end cavity with approved grease, fill the hub cavity with grease to the outer cup’s smallest diameter.
Page 202 14 Lubrication Conventional Trailer Axle Wheel-End Lubrication Intervals and Specifications Table L: Conventional Trailer Axle Wheel-End Oil Change Intervals and Specifications Outside Temperature °F °C Check Oil Meritor Specification Level Oil Change* Specification Approval Description Min. Max. Min. Max. 1,000 miles Linehaul and General O-76-A Gear MIL-PRF-2105...
Page 203 14 Lubrication Table M: Conventional Trailer Axle Greasing Intervals and Specifications Meritor NLGI Grease Outside Greasing Interval* Grease Specification Grade Description Temperature Linehaul and General Service: For Multi-Purpose O-617-A or 1 or 2 Lithium Refer to the 100,000 miles (160 000 km) or more a year, Grease O-617-B 12-Hydroxy...
Page 204 15 Specifications Torque Specifications 15 Specifications Figure 15.1 BRAKE MANUAL BEARING ADJUSTMENT — INNER NUT MANUAL BEARING ADJUSTMENT — OUTER NUT 4003370a Table N: Axle Torque Values Torque Range Description Lb-Ft Fastener Size 1. Hubcap bolts 15-30 20-41 0.31-18 2. Hub fill plug 15-20 20-27 0.62-11 (TR Model)
Page 205 15 Specifications Figure 15.2 POSITIVE BEARING ADJUSTMENT — OUTER NUT POSITIVE BEARING ADJUSTMENT — INNER NUT 4003371a Table O: Axle Torque Values Torque Range Description Lb-Ft Fastener Size 6. Adjusting nut, positive bearing adjustment 250-300 340-408 Size depends on axle model and adjustment method.
Page 206 15 Specifications Figure 15.3 4003372a Table P: Cam Brake Torque Values Torque Range Description Lb-Ft Fastener Size 9. Two-piece dust shield bolts, shown 25-35 34-48 0.38-16 10. Bolt-on bushing bolts 25-35 34-48 0.38-16 11 Cam bushing bolts 25-35 34-48 0.38-16 12.
Page 207 15 Specifications Figure 15.4 4003373a Table Q: Wedge Brake Torque Values Torque Range Description Lb-Ft Fastener Size 13. Actuator bolts 30-40 41-54 0.38-16 14. Support locknuts 10-15 13-20 0.31-16 15. Dust shield bolts 15-20 13-20 0.38-24 16. Support bolts 30-40 41-54 0.38-24 17.
Page 208 15 Specifications Figure 15.5 4003374a Table R: Disc Brake Torque Values Torque Range Description Lb-Ft Fastener Size 18. Slide pin retainer nut 60-80 82-109 0.75-16 19. Air chamber nut 80-125 109-170 0.62-11 Meritor Maintenance Manual 14 (Revised 03-07)
Page 209 SP Series Introduction This publication is to acquaint and assist you in installing and operating the Watson & Chalin SP Series suspension product line and is intended for use only with this product line. This manual includes installation and operating information on Watson & Chalin model numbers: Single Point Pedestal Single Point Straddle Mount...
Page 210 SP Series Before You Begin Before you begin to install the Watson & Chalin suspension system, you must: • Check your company specifications on suspension systems to be sure that the correct suspension system was chosen for the trailer. • Verify the frame width is within the allowable mounting range of the suspension and that the trailer crossmembers are correctly positioned.
Page 211 SP Series No welding of any suspension components is permitted except when specified by Watson & Chalin. Do not add lubrication to any air control systems as it can cause damage. Identifying Your Model It is important that you know what model number has been assigned to your assembly in case you ever need to contact Watson &...
Page 212 SP Series Note Some part numbers need more explanation; therefore, references have been given as a link to lead you to more details. Click the link to jump to the information or go to the page that contains the referenced information. Figure 2: Exploded View–TS Single Point Table 1 TS Single Point Parts List...
Page 213 SP Series Item # Description Quantity Part # Spring Cap SP-0003 Spring See Chart 1 Trunnion Cap/Spring Seat SP-0001 Trunnion Cap SP-0006 High Nut 1.125 UNF. Grade 8 10003 Cap Spring End See Chart 1 Capscrew .625 X 2.00 UNF. Grade 8 10034 Axle Seat/Spring Pin Assembly See Chart 1...
Page 214 SP Series Figure 3: Exploded View–SM Single Point Table 2 SM Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Straddle Trunion Tube Assembly Part number depends on spring centers Inner Straddle Plate Application Specific Outer Straddle Plate Application Specific U-bolt See Chart 2...
Page 215 SP Series Item # Description Quantity Part # Spring Cap SP-0003 Spring See Chart 2 Trunnion Cap/Spring Seat SP-0001 Trunnion Cap SP-0006 High Nut 1.125 UNF. Grade 8 10003 Cap-spring End See Chart 2 Capscrew .625 X 2.00 UNF. Grade 8 10034 Axle Seat/Spring Pin Assembly See Chart 2...
Page 216 SP Series Figure 4: Exploded View–SMR PAR Single Point Table 3 SMR PAR Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Straddle Trunnion Tube Assembly Part number depends on spring centers Inner Straddle Plate Application Specific Outer Straddle Plate Application Specific U-bolt 1.125UNFX12.5X5.75 Grade 8...
Page 217 SP Series Item # Description Quantity Part # Lower Spring Cap (USR) SP-0177 High Nut 1.125 Unf. 10003 Cap-spring End SP-0007 Capscrew .625 X 2.00 UNF. Grade 8 10034 Axle Seat/Spring Pin Assembly SP-0136 Lock Nut .625 UNF Gr C 10029 U-bolt .62X7.72 Grade 8 SP-0021...
Page 218 SP Series Figure 5: Exploded View–US Single Point Table 4 US Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Trunnion Tube Part number depends on spring centers U-bolt See Chart 3 Spring Cap SP-0003 Spring See Chart 3 Trunnion Cap/Spring Seat SP-0001...
Page 219 SP Series Item # Description Quantity Part # Axle Seat/Spring End Cap See Chart 3 High Nut 1.00 Unf. See Chart 3 Bottom Plate / Pin Assembly See Chart 3 Washer 1.00 See Chart 3 U-bolt See Chart 3 Polyurethane Bushing SP-0192 Washer 1.125 Hardened 10045...
Page 220 SP Series Figure 6: Exploded View–SMUS Single Point Table 5 SMUS Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Trunnion Tube Part number depends on spring centers Inner Straddle Plate Application Specific Outer Straddle Plate Application Specific U-bolt See Chart 4...
Page 221 SP Series Item # Description Quantity Part # Trunnion Cap/Spring Seat SP-0001 Trunnion Cap SP-0006 High Nut 1.125 UNF Grade 8 10003 U-bolt 1.00-14X11 Grade 8 SP-0020 Axle Seat/Spring End Cap See Chart 4 Bottom Plate Pin Assembly SP-0029 High Nut 1.00 UNF. 10031 Washer 1.00 17099...
Page 222 SP Series Figure 7: Exploded View–SM Single Point with End Caps Table 6 SM Single Point with End Caps Parts List Item # Description Quantity Part # Polyurethane Pad SP-0039 Trunnion Tube Part number depends on spring centers Inner Straddle Plate Application Specific Outer Straddle Plate Application Specific...
Page 223 SP Series Item # Description Quantity Part # High Nut 1.125 UNF Grade 8 10003 Cap-spring End SP-0015 Slide Plate Pin Assembly SP-0195 U-bolt 1.12-12X12 Grade 8 SP-0094 Washer 1.125 Hardened 10045 Polyurethane Bushing SP-0225 Axle Seat Propar 5” Dia. SP-0092 Chart 5 Model...
Page 224 SP Series Figure 8: Exploded View–TSR Single Point Table 7 TSR Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Washer Flat 4.12X6.00X.12 SP-0038 Trunnion Tube Part number depends on spring centers Trunnion Clamp Stand See Chart 6A U-bolt See Chart 6 Spring Cap...
Page 225 SP Series Item # Description Quantity Part # High Nut 1.125 UNF 10003 Cap-spring End See Chart 6 Capscrew .625 UNF See Chart 6 Axle Seat/Spring Pin Assembly See Chart 6 Lock Nut .625 UNF Grade 8 10029 U-bolt See Chart 6 Polyurethane Bushing SP-0193 Washer 1.125 Hardened...
Page 226 SP Series Figure 9: Exploded View–USR Single Point Table 8 USR Single Point Parts List Item # Description Quantity Part # Polyurethane Pad SP-0193 Trunnion Tube Part number depends on spring centers Trunnion Clamp Stand See Chart 7A U-bolt See Chart 7 Lower Spring Cap (USR) SP-0177 Spring...
Page 227 SP Series Item # Description Quantity Part # Axle Seat/Spring End Cap See Chart 7 Bottom Plate / Pin Assembly SP-0029 High Nut 1.00 UNF 10031 Washer Flat 1.06X1.75 Hardened 17099-01 Polyurethane Bushing SP-0192 Capscrew .75 UNF 2.50 Long Hardened 10896-01 Washer .75 Hardened 10043...
Page 228 SP Series Installation The following instructions are for installing the components of the Watson & Chalin SP Series Suspension systems. All model numbers in the series are installed using the same set of instructions. Watson & Chalin assumes that the correct suspension and axle were chosen based on the individual design criteria. Important Any deviation from the installation instructions must be approved in writing by Watson &...
Page 229 SP Series • Axle camber, if applicable, is located on top and perpendicular to flat of Spring End Pad Casting or 1/4” to the outside of vertical centerline of axle. • Axles are centered laterally on suspension. Measure from brake flange to centerline of spring, ensuring equal distance both sides.
Page 230 SP Series Preparing the Trailer Frame 1. To determine the centerline of tandem, measure from king-pin and scribe a vertical line on outside of both frame members. See figure 12 Figure 12: 2. Prepare the frame for installation of the suspension in one of the following ways: •...
Page 231 SP Series Figure 13: Assembling Tandem To Trailer 1. Install inside tires on suspension and roll unit under frame to proper centerline location. Note Installation of tires is not necessary at this time if a suitable dolly is used, or on trailer production lines where trailers are sometimes bottom side up.
Page 232 SP Series Figure 14: Axle Alignment After suspension installation, the axles must be aligned in relation to the trailer kingpin. • Measure the distance from the kingpin to the centerline of the front axle spindles. See figure 15 Dimensions A and B must be equal to each other within 1/8”. •...
Page 233 SP Series Figure 15: • Weld axles securely to Spring End Pad Castings, following the axle manufacturer’s welding recommendations, using 3/8” fillet welds on the front and rear of the axle seats. Use welding rod AWS-Spec. E-70xx or equivalent. See figure 16 Figure 16: Page 25...
Page 234 SP Series Final Checking • Check all welding to ensure proper welds at all locations indicated on drawings. • Check all nuts and bolts for proper tightness. (Make sure that all parts are tightened metal to metal.) • Install tires. Unit is ready to run. Torque Requirements Torque specifications listed below are applied to a nut, not the capscrew.
Page 235 Easy-Stop™ Enhanced Easy-Stop with PLC Trailer ABS Blink Code Diagnostic Guide Easy-Stop Easy-Stop 2S/1M, 2S/1M Basic 2S/2M*, 4S/2M*, 4S/3M* ECU/Modulator Valve Assembly ECU/Modulator Valve Assembly External modulator valve and cable required. Enhanced Easy-Stop with PLC 2S/1M Basic ECU/Single 2S/2M Standard ECU/Dual Modulator Valve Assembly Modulator Valve Assembly YE 2/6...
Page 236 Meritor WABCO Trailer ABS Quick Reference Guide Refer to Catalog PB-96133 for Additional Details Enhanced Easy-Stop Trailer ABS: Production Dates of March 2001 to Present ECU/Valve Assembly Description Service ECU Service Valve Bracket S400 500 101 0 2S/1M Trailers S446 108 201 0 S472 195 033 0 S478 407 058 4 S400 500 104 0...
Page 237 In-Line Filter Function: Prevents contamination of the trailer’s air system. Requires regular cleaning, but equipped with a bypass if needed. NOTICE: Trailer is equipped with an in-line filter to FILTER assist in protecting the air system brake valves. CARTRIDGE The in-line filter is serviceable and should be inspected and cleaned every 3 to 4 months.
Page 238 Troubleshooting and Repair BLINK CAUSE OF FAULT ACTION REQUIRED CODE No faults. System O.K. No action needed. Check sensor, sensor cable and cable connection; adjust Sensor BU1: Cable break, short circuit or out of sensor; or check for excessive hub runout, a sensor gap adjustment.
Page 239 Axle Wheel Bearing Installation Specifications Conventional Wheel-End Systems Initial Adjusting Final Adjusting Jam Nut Torque Acceptable Nut Torque Nut Torque Nut Size/Design Specification End Play Range Drive axles without 200 lb-ft (272 N m) 50 lb-ft (68 N m) Less Than 2-5/8" 200-300 lb-ft 0.001"-0.005"...
Page 269 PARTS REQUIRED FOR 6001115 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS FOR 3010971 RH HANGER BEAM ASSEMBLY - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS FOR 3010970 LH HANGER BEAM ASSEMBLY - LOOSEN PIVOT NUT. ITEM PART NO.
Page 271 PARTS REQUIRED FOR 6000119 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3010362 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3010361 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 272 PARTS REQUIRED FOR 6000119 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3010362 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3010361 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 273 PARTS REQUIRED FOR 6007739B024 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3017739B224 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3017739B124 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 274 PARTS REQUIRED FOR 6000057 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3010131 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3010130 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 275 PARTS REQUIRED FOR 6007754B108 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3017754B278 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3017754B178 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 276 PARTS REQUIRED FOR 6007744B107 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS REQUIRED FOR 3017744B200 (RH HGR/LBA) - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS REQUIRED FOR 3017744B100 (LH HGR/LBA) - LOOSEN 1.25 INCH NUT AT ECCENTRIC BOLT & REMOVE ANTI-TURN WASHER.
Page 277 PARTS REQUIRED FOR 6001033 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR PARTS FOR 3010997 RH HANGER BEAM ASSEMBLY TMC RECOMMENDED STANDARDS. PARTS FOR 3010996 LH HANGER BEAM ASSEMBLY - LOOSEN PIVOT NUT. ITEM PART NO.
Page 278 PARTS REQUIRED FOR 6001035 (CARTON OF PARTS) AXLE ADJUSTMENT PROCEDURE: PARTS FOR 3011001 RH HANGER BEAM ASSEMBLY - AXLE ALIGNMENT SHALL BE IN ACCORDANCE WITH SAE OR TMC RECOMMENDED STANDARDS. PARTS FOR 3011000 LH HANGER BEAM ASSEMBLY - LOOSEN PIVOT NUT. ITEM PART NO.
Page 279 Parts List ITEM PART NO. DESCRIPTION 1003586948C AIR SPRING 2B9-251/20F-2 #6948 1140674B105 HHCS 3/8" 16NC 1"LG. GRADE 5 1150555B112 L'NUT 1/2" 13NC NYLON INSERT GRADE 2 STOP WELD 1/2" 1160675B100 L'WASHER 3/8" S/T MED ZINC PLATED FROM EDGE, TYP .188 5970329 LIFT ARM ASSEMBLY, 240 30K O/S 8001834...
Page 281 Table of Contents Pg. 9 Pre-Installation, Axle Installation Pgs. 1-2 Application, Capacity, Standard Features, Options Pg. 10 Axle Installation (cont.), Preparing Trailer Frame Pg. 3 How To Order For Mounting Tandem Assembly Pg. 4 Axle Specifications and Mounting Heights Charts Pg.
Page 282 Options Standard 900 Series suspensions are available in capacities of 36,000, 42,000, 50,000, 60,000 and 70,000 lbs. Additionally, lightweight two-leaf and three-leaf units are available in capacities of 36,000, 44,000 and 50,000 lbs. Numerous mounting heights (Mtg./ht. = the vertical distance from the center line of the axle to the top of the trunnion hanger), axle and trunnion combinations are possible.
Page 283 Trunnion hanger heights (TH) of 2 1/2", 4 1/2", 6 1/2" and 8 1/2" are available. Trunnion Height (TH) Standard trunnion hanger centers (TC) are 22 1/8" (for 38" spring centers). Trunnion centers of 20 1/8" can be specified while maintaining 38"...
Page 284 Overslung Axle Specifications And Mounting Heights For Models: 900-36 through 900-44 with 2.5 Trunnion Ht., 5" Rd. & 5" x 5" Sq. Axles 900-50 through 900-70 with 4.5 Trunnion Ht., 5" Rd. & 5" x 5" Sq. Axles Gross Mounting Height Nominal Tandem Axle Spacing...
Page 285 900 Tapered Leaf and Multi-Leaf – 36 thru 70,000 (shown) Bill of Materials Quantity Overslung Trunnion Underslung Trunnion Overslung Underslung Overslung Underslung Item Part No. Axle Axle Axle Axle Description See Chart A, Page 8 Trunnion Hanger 10376-00 Hex Bolt 3/4" – 16 UNF x 4 1/2", GR5 20936-01 Washer, .173 x 5.75 OD x 4.03 ID, Flat Edge –...
Page 286 Overslung Trunnion — Overslung Axle Underslung Trunnion — Underslung Axle Pressure Plate (Item #26) Pressure Plate (Item #26) Required Required 5" x 5" Axle Only 5" x 5" Axle Only...
Page 287 900 — 36, 42, 44, 50, 60 and 70,000 Chart A – Trunnion Hanger (Item #1) Trunnion Hanger Height 2 1/2" 4 1/2" 6 1/2" 8 1/2" Part No. 850-01 10476-03 849-01 897-01 Chart B – Trunnion Tube (Item #4) Spring Centers/Trunnion Hanger Centers/Overall Length Unit Weight Capacity (lbs.)/ Wall Thickness...
Page 288 Installation Pre-Installation The 900 single point suspension is shipped assembled - except for the axle U-bolts, nuts and washers which are packaged separately. On each axle there is one adjustment plate factory welded, and one that is welded by the installer following axle alignment.
Page 289 Fig. 3 Axle Seat Axle Seat Axle Axle Overslung Axle Overslung Axle 3/8" 3/8" Axle Axle Axle Seat Axle Seat Underslung Axle Underslung Axle Caution: Do not attach welding ground clamps to U-bolts, Check tire clearance with the suspension at this time. See Fig.
Page 290 Installation Using Hutchens Mounting Brackets (Part #16793-01) Fig. 5 Side View (Typ) See Note 1 for mounting bracket welds 10.00" 1.00" Min. Trunnion Ht. Channel Brace – 2 req’d – See Chart J – Furnished by installer Minimum recommended size: .25 x 1.5 x 7 fabricated channel, A36 C6 x 8.2# structural channel, or similar.
Page 291 Mounting Tandem Assembly To Trailer Attach trunnion hanger to mounting bracket or Align the trunnion tube with the king pin. must be equal. See Fig. 6. trailer frame. Do not tighten bolts. Dimensions T and T Fig. 6 King pin center point After alignment, tighten the trunnion hanger fasteners to specification and recheck trunnion...
Page 292 Bump-Outs When rubber bushings are utilized in the trunnion connec- Spring end boxes are designed to accept bump-outs or stops, tion, the maximum oscillation at the trunnion hub should not which the installer should provide to assure tire clearance exceed 15° above or below horizontal. See Fig. 10. or to limit oscillation –...
Page 293 Numerical Listing of Parts Part No. Description Pg. # Part No. Description Pg. # 814-00 Rubber Pad – Plain 9936-04 Spring Seat – Adj., 6 RD, OS 817-00 Washer - 1/8 x 13/16 ID x 1 1/2 OD 9937-00 Spring End Cap – OS 820-00 Spring Clamp Plate 9938-00...
Page 294 The Hutch 900 Single Point Suspension offers the superior durability, reliability and performance that your fleet deserves – and it is backed by Hutchens’ on-time delivery, warranty, and commitment to after-sale support and service. Mtg. Ht. Mtg. Ht. Designed for heavy-duty, on and off-road applications, the Hutch 900 is a single point suspension that attaches to the trailer frame Overslung Axles - Overslung Trunnion Overslung Axles –...
Page 295 Important: Warning Decal Note When the installation of your “Hutch” suspension is complete and the trailer and/or subframe has been painted, a torque requirement decal (Part No. 16086-01) must be installed in plain view on the road side of the trailer immediately above the suspension. It is essential that the correct decal is in plain view on each trailer.
Page 296 ROOT 1/2" SECOND PASS 3/8" PASS THIRD 1/8" MAX PASS AXLE AXLE AXLE AXLE 1/2" BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT THIRD PASS WELD JOINT PREPARATION FIRST PASS SECOND PASS ARC START ARC START ARC STOP ARC STOP THIRD PASS...
Page 297 SUSPENSION CONTROL VALVES Air Bag Control Valve – Manual Operation 17610 17610 INFORMATION: Commonly used to control the inflation & deflation of air suspension bags Allows for movement of trailer back to dock without re-inflating air bags Operates with all air suspension systems Pull to manually exhaust air from air bags Push to refill air bags from reservoir PORT SIZES (NPT)
Page 298 RCA-215T - Trailer Nonsteerable – Auxiliary Axle Suspension Installation and Service Manual Suspension Identification ........2 Suspension System Serial Tag Installation ............. 3 Prior to Installation Axle Integration Axle Weld Standards Suspension Mounting Air Control Kit - Troubleshooting Maintenance ............9 Recommended Service Intervals Parts Illustration 215T Trailer Suspension...
Page 299: Suspension Identification
SUSPENSION IDENTIFICATION Introduction It’s important that the proper suspension model be chosen for the application in which it is to be used. The Ridewell Compact Air Ride (RCA) 215T Trailer Suspension is available for a wide range of appli- cations. The suspension can be purchased with or PART NO: without an integrated axle.
Page 300: Installation
INSTALLATION Prior to Installation Refer to the engineering drawing to confirm dimen- Installer Responsibilities sional requirements and the range of ride heights The installer of the suspension has the sole responsi- available. bility for proper attachment of the suspension system to the vehicle chassis.
Page 301: Axle Integration
Axle Integration Suspension systems are available with and without a factory integrated axle. Customer-supplied axle assem- blies must be positioned and oriented (rotated) properly before welding the axle. Use the top-center mark on the axle, if available, to identify the center of the axle and orient the axle as- sembly on the suspension.
Page 302 ROOT 1/2" SECOND PASS 3/8" PASS THIRD 1/8" MAX PASS AXLE AXLE AXLE AXLE 1/2" BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT THIRD PASS WELD JOINT PREPARATION FIRST PASS SECOND PASS ARC START ARC START ARC STOP ARC STOP THIRD PASS...
Page 303 Mounting the suspension to the frame Refer to the engineering drawing for the range of ride Shock Absorber Kit (Optional) heights available and clearance requirements . The shock absorber can be installed after the suspen- sion has been assembled and mounted on the vehicle. The suspension installer has the final responsibility Installation Procedure of attaching the suspension to the vehicle frame.
Page 304 Final Assembly and Inspection 1. Verify welds of frame hangers and air spring Regulate load with air spring pressure mounting plates. 2. Inspect for any loose or missing fasteners on the The load capacity of the auxiliary axle is ad- suspension assembly.
Page 305 Install air system components Pressure Connect the load and lift air springs and an air con- Protection Valve (PPV) (Required with air brakes) trol kit to the air system (Figure 6). Pressure Regulator The air control kit (ACK) consists of a pressure Air Tank regulator with a gauge connected to an air valve controlled by an electric switch or manual knob.
Page 306: Maintenance
MAINTENANCE A visual inspection of the suspension structure should be performed during each pre-trip/safety inspection. Ridewell Suspensions recommends the following minimum service intervals for standard duty, on-highway usage applications. More frequent intervals are recommended for heavier duty applications. Every 12,000 miles of use Daily/Pre-Trip Inspections __ Check tires for proper inflation, damage or __ Inspect air springs for any damage or excessive...
Page 307: Bushing Replacement Kit
Hanger Cross Channel (Customer-Supplied) Lock Lock Pivot Nut Mounting Plate (Flanged Lock Nut) (Air Spring) Hanger Wear Washer (Left-Hand) Pivot Bushing Alignment (Narrow) Washer Wear Washer Lock Nut Spring Adjuster (Load) Plate Flat Washer Pivot Bolt Lock Nut (Shear-Type) Lock Nut Air Spring (Lift) Beam/Bushing Assembly...
Page 308: Bushing Replacement Procedure
RCA 215T Trailer Suspension – Bushing Replacement Kit Bushing Bushing Rplcmnt Kit Rplcmnt Tool Torque Specification Suspension Type Part No. Part No. Pivot Hardware foot-pound Newton-meter All Models 6040078 6100044 500 ft-lb 678 N-m Traditional - Hex Head Cap Screw- HHCS/Lock Nut All Models 6040128...
Page 309 New Bushing Installation 1. Clean foreign debris/corrosion out of beam eye. Bushing Removal 2. Liberally apply P80 lubricant or soap solution to ® Cone Beam Eye the inside of the beam eye, the outside of the bush- Hex Nut Threaded Rod ing and the inside of the cone.
Page 310: Appendix
APPENDIX RCA-215T Trailer Suspension – Torque Specifications Torque Specifications foot-pound Newton-meter Fastener Type Size Pivot Bolt - (Shear-Type) Use a 1” drive impact wrench to tighten 7/8” - 9NC Pivot Nut - (Lock Nut) pivot bolt until Torx head is sheared off. Requires E-20 Torx socket (RW #6100054) ®...
Page 311: Axle Alignment
Axle Alignment Alignment should be performed on a level surface with the suspension at the desired ride height. Refer to the engineering drawing for the designed ride heights of the suspension model. Align the suspension per TMC or SAE recommended standards. On a multiple-axle vehicle, the forward axle is moved into the proper alignment, then the remaining axles are positioned so that they are parallel to the forward axle.
Page 312 Speed Set Alignment ™ The RCA-215 Auxiliary Axle Trailer Suspension is equipped with the Ridewell Speed Set alignment feature ® for simple, manual alignment of the axles. Axle alignment procedure 1. Loosen the pivot nut enough for beam to move within hanger.
Page 313: Warranty
WARRANTY Terms and coverage in this warranty apply only to the United States and Canada. Ridewell Suspensions warrants the suspension systems manufactured by it to be free of defects in mate- rial and workmanship. Warranty coverage applies only to suspensions that have been properly installed, maintained and operated within the rated capacity and recommended application of the suspension.
Page 314 RAR-240 Trailer Air-Ride Suspension Installation and Service Manual Suspension Identification ........2 Suspension System/Axle Serial Tag Installation ............. 3 Prior to Installation Axle Integration Axle Weld Standards Suspension Mounting Troubleshooting HCV Installation Maintenance ............8 Recommended Service Intervals Parts Illustration 25K/30K Overslung Suspension- 25K/30K Underslung Suspension 25K/30K Yoke Mount Suspension...
Page 315 SUSPENSION IDENTIFICATION Introduction It’s important that the proper suspension model be chosen for the application in which it is to be used. The Ridewell Air Ride (RAR) 240 Trailer Suspen- sion is available in an overslung, underslung or yoke mount configuration for use in a range of applica- PART NO: tions.
Page 316 INSTALLATION Prior to Installation Installer Responsibilities Refer to the engineering drawing to confirm dimen- sional requirements and the range of ride heights The installer of the suspension has the sole responsi- available. bility for proper attachment of the suspension system to the vehicle chassis.
Page 317 Axle Integration Suspension systems are available with and without a factory integrated axle. Customer-supplied axle assem- blies must be positioned and oriented (rotated) properly before welding the axle. Use the top-center mark on the axle, if available, to identify the center of the axle and orient the axle as- sembly on the suspension.
Page 318 ROOT 1/2" SECOND PASS 3/8" PASS THIRD 1/8" MAX PASS AXLE AXLE AXLE AXLE 1/2" BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT THIRD PASS WELD JOINT PREPARATION FIRST PASS SECOND PASS ARC START ARC START ARC STOP ARC STOP THIRD PASS...
Page 319 Mounting the suspension to the frame Final Assembly and Inspection Refer to the engineering drawing for the range of ride heights available, torque values, spacing and clear- • Verify the welds of the hanger and air spring ance requirements of the suspension. mounting plates.
Page 320 Install the height control valve The Ridewell Extreme Air Height Control Kit (HCK) automatically adds and exhausts air from the air sus- ® pension to maintain the vehicle ride height as loads increase and decrease. The (HCK) assembly consists of a lever arm connected to the height control valve (HCV) and a vertical rod arm (vertical linkage) connected to the suspension/axle (Figure 6).
Page 321 MAINTENANCE A visual inspection of the suspension structure should be performed during each pre-trip/safety inspection. Ridewell Suspensions recommends the following minimum service intervals for standard duty, on-highway usage applications. More frequent intervals are recommended for heavier duty applications. Daily/Pre-Trip Inspections Every 12,000 miles of use ___ Check tires for proper inflation, damage or ___ Inspect air springs for any damage or excessive...
Page 322 Figure 7. RAR-240 - 25K Trailer Lock Nut Suspension – Pivot Nut Lock Nut Overslung. (Lock Nut) Hanger Lock Nut (Left-Hand shown) Bolt Mounting Plate (Air Spring) Shock Absorber Anti-Turn Washer Pivot Bolt (Eccentric Bolt) Bolt Lock Nut Spring Trailing Arm Beam Assembly (LH shown) Wear Washer Pivot...
Page 323 Air Spring Mounting Plate Pivot Nut (Alternate) (Lock Nut) Hanger (Left-Hand shown) Lock Nut Lock Nut Lock Nut Bolt Pivot Bolt Shock (Eccentric Bolt) Absorber Mounting Plate Lock Nut Anti-Turn (Air Spring) Washer Wear Washer Lock Nut Bolt Flat Washer Bolt (Bushing - Clamp) Spring...
Page 324 Crossmember on trailer frame Shock absorber mounting bracket Bushing Sleeve (Welded into trailer frame) Lock Nut Bolt Trailer Frame (Left-Hand shown) Lock Nut Lock Nut Shock Absorber Lock Nut Mounting Plate (Air Spring) Bolt Wear Washer Pivot Bushing Assembly (Metal Sleeve) Wear Washer Pivot Nut (Lock Nut)
Page 325 RAR-240 Trailer Suspension – Bushing Replacement Kit Replacement Kit Torque Specifications Suspension Type Part No. Pivot Hardware foot-pound Newton-meter 15K - Underslung (u/s) (2400080) 6040029 Eccentric Bolt 1,000 ft-lb 1,350 N-m 25K - Standard underslung (u/s) 6040029 Eccentric Bolt 1,000 ft-lb 1,350 N-m or overslung (o/s) 30K - Standard u/s or o/s...
Page 326 Bushing Replacement Procedure – Yoke Mount Suspension Park the vehicle on a level surface. Chock wheels to keep vehicle from moving. Raise vehicle to height that removes load from suspension and support with jack stands. Disconnect the linkage from the height control valve(s), if necessary.
Page 327 APPENDIX RAR-240 Trailer Suspension - Torque Specifications Torque Specifications foot-pound Newton-meter Fastener Type Size Pivot Bolt (Eccentric Bolt) 1 1/4”-7NC 1,000 ft-lb 1,350 N-m Pivot Nut (Lock Nut) Bolt/Lock Nut (Shock Absorber) 3/4”-10NC 200 ft-lb 270 N-m Bolt/Lock Nut (Air Spring) 1/2”-13NC 25 ft-lb 35 N-m...
Page 328 Axle Alignment Alignment should be performed on a level surface with the suspension at the desired ride height. Refer to the engineering drawing for the designed ride heights of the suspension model. Align the suspension per TMC or SAE recommended standards. On a multiple-axle vehicle, the forward axle is moved into the proper alignment, then the remaining axles are positioned so that they are parallel to the forward axle.
Page 329 WARRANTY Terms and coverage in this warranty apply only to the United States and Canada. Ridewell Suspensions warrants the suspension systems manufactured by it to be free of defects in mate- rial and workmanship. Warranty coverage applies only to suspensions that have been properly installed, maintained and operated within the rated capacity and recommended application of the suspension.
Page 330 RUL-245T - Trailer NonSteerable - Auxiliary Axle Suspension Installation and Service Manual Suspension Identification .........2 Suspension System/Axle Serial Tag Installation ............3 Axle Integration Axle Weld Standards Suspension Mounting Air Controls - Troubleshooting Maintenance ............9 Recommended Service Intervals Parts Illustration 245T - Trailer Suspension Bushing Replacement Kit Bushing Replacement Procedure Appendix ............
Page 331: Suspension Identification
SUSPENSION IDENTIFICATION Introduction It’s important that the proper suspension model be chosen for the application in which it is to be used. The Ridewell Universal Lift (RUL) - 245T Trailer Sus- pension is available for use in a range of applications. The suspension can be purchased with or without an PART NO: integrated axle.
Page 332: Installation
INSTALLATION Prior to Installation Refer to the engineering drawing to confirm dimen- Installer Responsibilities sional requirements and the range of ride heights The installer of the suspension has the sole responsi- available. bility for proper attachment of the suspension system to the vehicle chassis.
Page 333: Axle Integration
Axle Integration Suspension systems are available with and without a factory integrated axle. Customer-supplied axle assem- blies must be positioned and oriented (rotated) properly before welding the axle to the axle seats. The axle assembly should be installed so that the camshafts, when activated, rotate in the same direc- tion as the wheels.
Page 334 ROOT 1/2" SECOND PASS 3/8" PASS THIRD 1/8" MAX PASS AXLE AXLE AXLE AXLE 1/2" BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT BEAM AXLE SEAT THIRD PASS WELD JOINT PREPARATION FIRST PASS SECOND PASS ARC START ARC START ARC STOP ARC STOP THIRD PASS...
Page 335 Mounting the suspension to the frame Final Assembly and Inspection Refer to the engineering drawing for the range of ride heights available and clearance requirements . • Verify the welds of the hanger and air spring mounting plates. The suspension installer has the final responsibility •...
Page 336 Installation and Operation Check 1. Check attachment of frame hangers and air spring Air springs pressure regulates axle load mounting plates. The load capacity of the auxiliary axle is adjusted 2. Inspect for any loose or missing fasteners on the by increasing or decreasing the pressure to the air suspension assembly.
Page 337 Install air system components Pressure Protection Valve (PPV) Connect the load and lift air springs and an air con- (Required with air brakes) trol kit to the air system (Figure 6). Pressure Regulator The air control kit (ACK) consists of a pressure Air Tank regulator with a gauge connected to an air valve controlled by an electric switch or manual knob.
Page 338: Maintenance
MAINTENANCE A visual inspection of the suspension structure should be performed during each pre-trip/safety inspection. Ridewell Suspensions recommends the following minimum service intervals for standard duty, on-highway usage applications. More frequent intervals are recommended for heavier duty applications. Daily/Pre-Trip Inspections Every 12,000 miles of use __ Check tires for proper inflation, damage or __ Inspect air springs for any damage or excessive...
Page 339: Trailer Suspension
Lock Nut Mounting Plate (Air Spring) Hanger (Left-Hand shown) Alignment Washer Lock Nut Spring Adjuster Plate (Load) Air Spring-LH Pivot Bolt (See drawing) (Shear-Type) Wear Washer Flat Washer Air Spring (Lift) Lock Nut Pivot Lock Nut Bushing Wear Washer Lock Nut Axle Beam/Bushing Assembly (LH shown)
Page 340: Bushing Replacement Procedure
RUL-245T - Trailer Suspension – Bushing Replacement Kit Bushing Bushing Rplcmnt Kit Rplcmnt Tool Torque Specification Suspension Type Part No. Part No. Pivot Hardware foot-pound Newton-meter All Models 6040078 6100044 500 ft-lb 678 N-m Traditional - Hex Head Cap Screw- HHCS/Lock Nut All Models 6040128...
Page 341 Replacement w/ 6100044 (continued) New Bushing Installation Replacement: 1. Use a wire brush to clean any foreign debris and Factory Bonded Wide Bushing (6 3/4”) in RUL- any corrosion out of the beam eye. 245 Suspensions Manufactured Before 2009: 2. Liberally apply P80 lubricant or soap solution to ®...
Page 342: Appendix
APPENDIX RUL-245T - Trailer Suspension – Torque Specifications Torque Specifications foot-pound Newton-meter Fastener Type Size Pivot Bolt - (Shear-Type) Use a 1” drive impact wrench to tighten 7/8” - 9NC Pivot Nut - (Lock Nut) pivot bolt until Torx head is sheared off. Requires E-20 Torx socket (RW #6100054) ®...
Page 343: Axle Alignment
Axle Alignment Alignment should be performed on a level surface with the suspension at the desired ride height. Align the suspension per TMC or SAE recommended standards. On a multiple-axle vehicle, the forward axle is moved into the proper alignment, then the remaining axles are positioned so that they are parallel to the forward axle.
Page 344 Speed Set Alignment ™ The RUL-245T Auxiliary Axle Trailer Suspension is equipped with the Ridewell Speed Set alignment feature ® for simple, manual alignment of the axles. Axle alignment procedure 1. Loosen the pivot nut enough for beam to move. Torx 2.
Page 345: Warranty
WARRANTY Terms and coverage in this warranty apply only to the United States and Canada. Ridewell Suspensions warrants the suspension systems manufactured by it to be free of defects in mate- rial and workmanship. Warranty coverage applies only to suspensions that have been properly installed, maintained and operated within the rated capacity and recommended application of the suspension.
Page 346 SUSPENSION CONTROL VALVES Air Bag Control Valve – Manual Operation 17610 17610 INFORMATION: Commonly used to control the inflation & deflation of air suspension bags Allows for movement of trailer back to dock without re-inflating air bags Operates with all air suspension systems Pull to manually exhaust air from air bags Push to refill air bags from reservoir PORT SIZES (NPT)
Page 347 HAND CONTROL VALVES Lever Control Valves OUT (2) INFORMATION: Used for a variety of applications Manual operation REPAIR KIT 110242 PORT SIZES (NPT) PART NAME NUMBER PLATE Inlet Outlet (2) 21600 1/8" 1/8" 21600D 1/8" 1/8" 21600-2 None 1/8" 1/8" 110167 None 1/8"...
Page 348 SERVICE RELAY VALVES Service Relay Valves (2 Delivery Ports) CONT DEL (2) INFORMATION: Nipple mounted 110360 & 110410 are used primarily for single axle trailer service brakes or tandem axle by axle trailer brake designs 110365 may be used as a frame mounted version of 110360 or as a Control Line Valve to replace 110463 or 110464 110412 &...
Page 349 TP-20212 Revised 08-05 Enhanced Easy-Stop™ Trailer ABS 2S/1M Basic with PLC Installation Instructions Installation Guide TP-20212 Revised 1 Technical Bulletin 08-05 Hazard Alert Messages Preparation Read and observe all Warning and Caution hazard alert messages in WARNING this publication. They provide information that can help prevent To prevent serious eye injury, always wear safe eye protection serious personal injury, damage to components, or both.
Page 350 Have the following installation material available. Study the ECU/single modulator valve assembly. Note the location of the various ports and electrical connections on ECU/single modulator valve assembly the ECU. Figure 1. Power cable or power/diagnostic cable Sensor extension cables (two pieces) Sensors (two) for non-ABS-prepped axles ABS Indicator Label (TP-95172) 5/8-inch O.D.
Page 351 Installation Bracket-Mounted to Cross Member of Vehicle Install a 3/4-inch NPTF fitting in the supply port (Port 1). I. Install the ECU/single modulator valve Use a 3/4-inch NPTF pipe plug to plug the unused supply assembly. port (Port 1). Apply SAE-standard, DOT-approved Teflon The assembly may be mounted on the air tank or on the cross tape or paste-type thread sealant to all pipe threads beyond member of the vehicle.
Page 352 Connect the air delivery lines from the service chambers to the Figure 5 ECU/single modulator valve assembly Port 2 (3/8-inch NPTF). Figure 4. Attach the opposite ends of the air delivery lines to the SENSOR appropriate brake chambers (3/8-inch NPTF). EXTENSION CABLE Figure 4...
Page 353 Plug the sensor extension cable into the ECU/single modulator IV. Install the power or power/diagnostic valve assembly. To secure the connection, push the sensor cable. retainer clip DOWN. Retainer clips must fit in the groove of the Identify the type of cable to be installed. sensor connectors to ensure correct connection.
Page 354 Pull the hinged power connector retaining clip on the Install the ABS indicator lamp on the trailer. Refer to the vehicle ECU/single modulator valve assembly DOWN to secure specification sheet for the exact location of the indicator lamp. the connection. Use a DOT-approved lamp with ABS etched on the lens (available from major trailer parts suppliers).
Page 355 Typical Easy-Stop™ Trailer ABS Installations Refer to Figure 11 for typical Easy-Stop™ trailer ABS installations. Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. Figure 11 Typical Tandem Axle Trailer Spring Suspension Installation with Sensors on Front Axle Typical Tandem Axle Trailer...
Page 356 End of Line Testing Figure 12 End of line testing is required on all Enhanced Easy-Stop™ installations. To run these tests, Meritor WABCO recommends you use TOOLBOX™ Software. TOOLBOX™ Software and general test procedures are included in this bulletin. If you are using a Pro-Link, refer to the operating manual for test instructions.
Page 357 End of Line Test with TOOLBOX™ Software Sensor Orientation Test The sensor orientation test must be performed as part of the end of Verify Correct Valve and Lamp Installation line testing procedure. To verify valve and lamp installations with TOOLBOX™ Software: Sensor Orientation Test Screen At the Trailer Main Screen, click on Component Test, then Before beginning this test, look at the ECU to see if the wheel end...
Page 358 Click on Front or Rear in the Sensors Facing field to select Follow the screen prompts, starting with 1, to rotate each the mounting orientation of the ECU/single modulator valve sensed wheel end at a rate of 1/2 revolution per second. This assembly.
Page 359 Sensor Gap Adjustment Trailer Identification Push the sensor into its holder until it contacts the tooth wheel. At After ensuring the Enhanced Easy-Stop™ trailer ABS has been installation, there must be no gap between the sensor and the tooth correctly installed, attach the ABS indicator label included with the wheel.
Page 360 Appendix Installing Sensors on Non-ABS-Prepped Route the sensor cable toward the brake chamber, over the brake spider or through the pre-stamped hole dedicated to Axles ABS sensors. Route to the back side of the axle. Secure the Sensor locations vary due to suspension type. Meritor WABCO cable to the axle between the brake spider and the suspension recommends placing the sensor on the axle that will provide the brackets.
Page 363 Control Valves Quick Reference View the full Sealco product line on the web at www.sealcocvp.com (� __ S_u_ s _ p e_ n_ s_i _ o _ n _E_x_h _ a _u_ s t_ V_ a_ l_ v _ e _W_i_ t h _R _ e _ s e _ t_P_ i_lo _ t_P_ o_ rt_�) (�...
Page 365 Vocational Truck Valve Program Bulletin HY14-2409/US General Assembly Information Open-Center Directional Control Valves General Valve Assembly Information The Basics Every valve has the following elements: • • Inlet Outlet • • Main relief Section seals • • Work sections Stud kit to hold the assembly in place The valve inlet is connected directly to the outlet coming from the hydraulic pump, and the...
Page 366 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information V20 Open-Center Directional Control Valves V20 Inlets Specifications Nominal Up to 95 LPM Flow (25 GPM) Operating Up to 240 Bar Pressure (3500 PSI) Standard Mid Inlets Part Number Model Number Description Porting 08650029 20-LC-12...
Page 367 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information V20 Open-Center Directional Control Valves V20 Work Sections Model V20 double-acting cylinder sections versus V20 motor spools cannot be visually determined simply by looking at the valves. It is important to keep the valves properly marked during the assembly process.
Page 368 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information V20 Open-Center Directional Control Valves V20 Outlets The Power Beyond Sleeve must be ordered separately and does not come installed. Standard Outlet Power Beyond Outlet Power Beyond Sleeve Part Number Model Number Description Porting 13650146...
Page 369 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information V20 Open-Center Directional Control Valves Stud Kits Mid Inlets and Utility Sections count as a work section when selecting stud kits. Part Model Number Number Description 08650087 K-20-1 1 Work Section 08650088 K-20-2 2 Work Sections 08650089...
Page 370 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information VA20 and VG20 Open-Center Control Valves VA20 and VG20 Inlets / Main Relief Valves Specifications Nominal Up to 170 LPM Flow (45 GPM) Operating VA20 Up to 172 Bar (2500 PSI) Pressure VG20 Up to 241 Bar (3500 PSI) Part Number Model Number...
Page 371 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information VA20 and VG20 Open-Center Control Valves VA20 and VG20 Work Sections Spring Return Part Number Model Number Description Porting 347-9172-003 DVA20-DA7 Low Boy Double-Acting Cylinder Spool SAE 12 347-9172-006 DVA20-MA7 Low Boy Double-Acting Motor Spool SAE 12 347-9171-003 DVA20-SA7...
Page 372 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information VA20 and VG20 Open-Center Control Valves VA20 and VG20 Positioner Kits Part Number Model Number Description 391-1873-206 DV20-K-113 Pneumatic Shifter 391-1873-020 DV20-K-101 3-Position Detent 391-1873-019 DV20-K-100 Spring Center VA20 and VG20 Stud Kits Part Nmber Model Number Description 391-1873-045...
Page 373 Vocational Truck Valve Program Bulletin HY14-2409/US Ordering Information VA and VG20 Open-Center Control Valves VA and VG Work Port Relief Part Number Model Number Description 391-1873-006 DV-PRVAC Screw Adjustable Work Port Relief 391-1873-010 DV-AC Anti-Cavitation Check Valve 391-1873-007 DV-PRV-1 Work Port Relief 34 - 69 Bar (500 - 1000 PSI) 391-1873-008 DV-PRV-2 Work Port Relief 69 - 172 Bar (1000 - 2500 PSI)
Page 374 Bulletin HY14-2409/US Terms of Sale with Warranty Limitations Offer of Sale The goods, services or work (referred to as the “Products”) offered by Parker-Hannifin Corporation, its subsidiaries, groups, divisions, and authorized distributors (“Seller”) are offered for sale at prices indicated in the offer, or as may be established by Seller. The offer to sell the Products and acceptance of Seller’s offer by any customer (“Buyer”) is contingent upon, and will be governed by all of the terms and conditions contained in this Offer of Sale.
Page 375 Parker Safety Guide for Selecting and Using Hydraulic Valves and Related Accessories WARNING: Failure or improper selection or improper use of Parker Hydraulic Valve Division (HVD) Valves or related accessories (“Products”) can cause death, personal injury and property damage. Possible consequences of failure or improper use of these Products include but are not limited to: ■...
Page 376 VALVE INSTALLATION INSTRUCTIONS Component Inspection: Prior to use, a careful examination of the Valve(s) must be performed. The Valve intended for use must be checked for correct style, size, catalog number and external condition. The Valve must be examined for cleanliness, absence of external defects or gouges, cracked or otherwise deformed parts or missing items.
Page 377 347-9201-817 VA20 NPT Ports 4 Way 3 Position Manual Inlet DVA20-A440 347-9175-001 Relief Valve DVA20-MRV 391-1873-001 Work Section DVA20-DA3 346-9172-002 Outlet DVA20-TR44 347-9176-001 Stud Kit DVA20-SK-1 391-1873-045...
Page 378 HVD Valve Components Open Center V20 VA20 VA35...
Page 379 Work Section Basic Construction Inlet All Valves Have And Inlet – Outlet And Work Sections Outlet Work Port Plugs This is Where Work Port Reliefs are Installed Main Relief Torque for Valves Studs Main Relief Gresen V20 Series 384 In. lbs Commercial DVA20 Series 350 In.
Page 380 Basic Work Section All Work Sections Have Plugged Accessory Ports Work Port B Work Port A Work Port Relief Work Port Relief Note: Commercial Low Boy Work Sections do not Provide for Work Port Relief Ports...
Page 381 V20 Flow and Pressure Rating Flow Rating 25 GPM Pressure Rating 3500 PSI Inlets & Outlets NPT ¾” SAE 12 Work Ports NPT ½” SAE 10...
Page 382 V20 NPT Pipe Thread NPT (Pipe Thread) Description V20 Inlet Gresen # 20-LC-75 08650030 V 20 Inlet ¾ NPT Add Relief RP51A-3000 08650421 Main Relief Adjustable WH-1700 08650418 Main Relief Non Adjustable WH-1950 08650419 Main Relief Non Adjustable WH-2550 08650420 Main Relief Non Adjustable 20-75-CF 08650001...
Page 383 V20 SAE Straight Thread O-Ring V20 INLET Gresen# DESCRIPTION 20-LC-12 08650029 V20 Inlet SAE 12 Plugged Relief RP51A-3000 Same Main Relief Adjustable 3000 PSI WH-1700 08650418 Main Relief Non Adjustable WH-1950 08650419 Main Relief Non Adjustable WH-2550 08650420 Main Relief Non Adjustable 20-12-CF 08650003 Combined Flow Mid-Inlet V20 OUTLETS...
Page 384 V20 Work Port Accessories...
Page 385 V20 Handle and Stud Kits...
Page 386 DVA DVG 20 Flow and Pressure Rating Flow Rating 40 GPM Pressure 2500 PSI 3500 PSI Inlets & Outlets 1” Work Ports ¾”...
Page 387 DVA20 NPT Pipe Thread DVA Inlets 10 Digit # Description DVA20-A440 347-9175-001 Inlet 1” Pipe (Need to Add Relief) DVA20 MRV & MRV Plugs DVA20-MRV 391-1873-001 500 TO 2000 PSI Relief DVA20-MRVP 391-1873-002 Main Relief Plug DVA20 Outlets DVA20-TR44 347-9176-001 Standard Outlet 1”...
Page 388 DVA20 SAE Straight Thread O-Ring DVA20 Inlets 10 Digit Code DVA20-A880 347-9175-002 Inlet SAE 16(Need to add Relief Valve) DVA20 MRV & MRV Plugs DVA20-MRV 391-1873-001 500-2500 PSI Relief DVA20-MRVP 391-1873-002 Main Relief Plug DVA20 Outlets DVA20-PB08 347-9176-005 Power Beyond Outlet/ Top Porting DVA20-TR88 347-9176-002 Standard Outlet...
Page 389 DVG20 SAE Straight Thread O-Ring DVG20 Inlets 10 Digit # Description DVG20-A880 347-9175-010 Inlet SAE 16 DVG20 Main Relief Valve DVG20-HMRV 391-1873-128 Main Relief 2500 to 3500 PSI DVG20-MRVP 391-1873-002 Main Relief Valve Plug DVG20 Outlets DVG20-TTR88 347-9176-007 Standard Outlet SAE 16 DVG20-TPB80 347-9175-010 Outlet Power Beyond SAE 16...
Page 390 DVA DVG 20 Accessories Stud Kits 10 Digit # # Work Sections DVA20-SK-1 391-1873-045 DVA20-SK-2 391-1873-046 DVA20-SK-3 391-1873-047 Three DVA20-SK-4 391-1873-048 Four DVA20-SK-5 391-1873-049 Five DVA20-SK-6 391-1873-050 DVA20-SK-7 391-1873-051 Seven DVA20-SK-8 391-1873-052 Eight DVG20-TSK-1 391-1873-129 DVG20-TSK-2 391-1873-130 DVG20-TSK-3 391-1873-131 Three DVG20-TSK-4 391-1873-132 Four...
Page 391 DVA DVG 20 Accessories Handle Assemblies 10 Digit # Description DV20-H-3 391-1873-093 6” Std Handle DV20-H-4 391-1873-098 8” Std Handle DV20-H-6 391-1873-061 6” Handle for High Boy DV20-H-8 391-1873-062 8” Handle for High Boy Seal Kits DV20-K-1 391-1873-035 Work Section Assembly DV20-K-2 391-1873-036 Work Section , Spool, Check Seals...
Page 392 DVA DVG 35 Flow and Pressure Ratings Flow Rating 70 GPM Pressure Rating 2500 PSI 3500 PSI Inlet and Outlets 1 ¼” Work Ports 1”...
Page 393 DVA35 NPT Pipe Thread DVA35 Inlet 10 Digit # Description DVA35-A440 348-9175-001 Inlet 1” Pipe (Add Relief) DVA35 Main Relief Valve DVA35-MRV-1 391-1873-003 800-2000 PSI DVA35-MRV-2 391-1873-004 2000-2500 PSI Outlet DVA35-TR55 348-9176-001 Standard Outlet DVA35-PB55 348-9176-003 Power Beyond Work Sections Low Boy DVA35-SA4 348-9171-002...
Page 394 DVA35 SAE Straight Thread O-Ring DVA35 Inlet 10 Digit # Description DVA35-A880 348-9175-005 Inlet SAE 16 Need To Add Relief DVA35-A980 348-9175-002 Inlet SAE 20 Need To Add Relief Main Relief DVA35-MRV-1 391-1873-003 800-2000 PSI DVA35-MRV-2 391-1873-004 2000-2500 PSI Outlet DVA35-TR99 348-9176-002 Standard Outlet...
Page 395 DVG35 SAE Straight Thread O-Ring DVG35 Inlets 10 Digit # Description DVG35-A880 348-9175-008 Standard Inlet SAE 16 DVG35-A980 348-9175-004 Inlet SAE 20 DVG35 Main Relief DVG35-HMRV 391-1873-137 2800 to 3500 PSI DVG35-MRVP 391-1873-005 Main Relief Plug DVG35 Outlets DVG35-TTR99 348-9176-007 Standard Outlet SAE 20 DVG35-TPB99 348-9176-008...
Page 396 DVA DVG 35 Valve Accessories DVA/DVG Stud 10 Digit # # Work Sections DVA35-SK-1 391-1873-053 DVA35-SK-2 391-1873-054 DVA35-SK-3 391-1873-055 Three DVA35-SK-4 391-1873-056 Four DVA35-SK-5 391-1873-057 Five DVA35-SK-6 391-1873-058 DVA35-SK-7 391-1873-059 Seven DVA35-SK-8 391-1873-060 Eight DVG35-TSK-1 391-1873-138 DVG35-TSK-2 391-1873-139 DVG35-TSK-3 391-1873-140 Three DVG35-TSK-4 391-1873-141...
Page 397 DVA DVG 35 Valve Accessories Handle Assembly 10 Digit # Description DV35-H-3 391-1873-096 6” Standard Handle DV35-H-4 391-1873-097 8” Standard handle DV35-H-6 391-1873-064 6” Handle For High Boy DV35-H-8 391-1873-065 8” Handle For High Boy Seal Kits DV35-K11 391-1873-040 Work Section Assembly Seals DV35-K12 391-1873-041 Work Section, Spool, Check Seals...
Page 398 VG35EH Open-Center Valve Directional Control Build Program with Pricing Addendum to PL HY14-2000/US Bulletin HY14-2007-B1/US Effective: January 1, 2008...
Page 399 Open-Center Directional Control Valve Bulletin HY14-2007-B1/US Contents VG35EH Build Program Technical Information General Description ............................1 Operation ................................1 Features ................................1 Speciﬁ cations ..............................2 Weights ................................2 Connections ..............................2 Ordering Information Inlet Covers ..............................3 Main Relief covers ............................3 Outlet Covers ..............................3 Power Beyond Outlet Covers ..........................3 Stud Assembly Kits............................4 Pilot Generating/Regulating Section ........................4 Work Sections ..............................4...
Page 400: General Description
Open-Center Directional Control Valve Bulletin HY14-2007-B1/US Technical Information VG35EH Build Program General Description The VG35 has been a strong and reliable player in the 170-246 LPM (45-65 GPM) open-center, directional control valve market for many years. Now it has a new, electrohydraulic package designed for open-center systems and for those customers wanting to take ma- chine control to the next level.
Page 401: Specifi Cations
Open-Center Directional Control Valve Bulletin HY14-2007-B1/US Technical Information VG35EH Build Program Speciﬁ cations Solenoid Speciﬁ cations Voltage 12 or 24 VDC Pressures Pump Inlet Ports: 275 Bar (4000 PSI) Service Ports: 45 Bar (5000 PSI) Frequency 100 ±10 Hz Pilot 35 Bar (508 PSI) Pilot: 35 Bar (508 PSI) (input or internal supply)
Page 402 Open-Center Directional Control Valve Bulletin HY14-2007-B1/US Ordering Information VG35EH Build Program VG35EH Inlet Covers Poduct Code Part Number List Price SAE-16 Top SAE-16 Side SAE-20 Top SAE-20 Side Blocked Pilots DVG35-A990 348 9175 009 $192.44 DVG35-A880 348 9175 008 $192.44 VG35-A990-BP 348 9195 098 $225.50...
Page 403 Open-Center Directional Control Valve Bulletin HY14-2007-B1/US Ordering Information VG35EH Build Program VG35EH Stud Assembly Kits No of Product Code Part Number List Price Sections DVG35-TSK-1 391 1873 138 $62.50 DVG35-TSK-2 391 1873 139 $69.75 DVG35-TSK-3 391 1873 140 $80.59 DVG35-TSK-4 391 1873 141 $89.64 DVG35-TSK-5...
Page 435 -Series Directional Control Valve Formerly the RSM290 Series Key valve features Technical data DX-6 is a sectional valve designed for Pressures / Flows max. operating pressures up to 5000 psi (350 bar) and max. pump flows up to 180 Max. operating pressure set per port: l/min with “Q-inlet”.
Page 436 General overview Port Sizes for US Models SAE12 P2 SAE12 The drawing shows a 4-sectional valve SAE16 T2 SAE20 with inlet and outlet. The sections are SAE16 T4 SAE16 with various types of spool controls. A&B SAE12 SAE ports are shown in the table. SAE04 SAE04 SAE06...
Page 437 Dimensions and weight Port Sizes for US Models SAE12 P2 SAE12 The drawing shows a 4-sectional SAE16 T2 SAE20 valve with inlet and outlet. The valve SAE16 T4 SAE16 is configured for left hand inlet and A&B SAE12 shows the sizes of the ports for a SAE04 SAE04 valve with G-ports and the drawing...
Page 438 Dimensions and weight Port Sizes for US Models SAE12 P2 SAE12 The drawing shows a 4-section SAE16 T3 SAE16 valve with standard inlet section, SAE12 A&B working sections manual operated SAE04 and a multisection/outlet. SAE ports are shown in the table. M10x1.5 (x4) A-side G ¾"...
Page 439 Inlet Section I23B SAE12 SAE16 SAE04 SAE12 The standard inlet section I23B has two pump connections P1 and P2, a gauge port PM1 to monitor system pressure and a tank connection T1. Direct acting main relief valve (TBD201), Inlet I23B and an unloading function via 2/2 solenoid valve (EU) EU24 Unloading valve...
Page 440 Inlet section I13B SAE12 SAE16 SAE04 SAE12 Flow control function The inlet section I13B with its integral Q-function provides by- pass of pump flow to tank in idling condition, thereby reducing pressure drop and heat generation. It also reduces flow forces I13B Inlet section and makes the control response to large extent unaffected by...
Page 441 Working section S14L A-side SAE12 B-side SAE12 Working section S14L for both manual and remote operation. The example shows a section configured for manual operation with the spring centering spool control on A-side and encapsulated lever mechanism on B-side spool actuator. The section S14L includes a loadcheck valve.
Page 442 Work section S34L A-side B-side SAE12 SAE12 Working section S34L for both manual and remote operation. The example shows a section configured for electro hydraulic remote control with the spring centering spool control on A-side S34L Section and the proportional solenoids on the B-side. The section S34L includes loadcheck valve and cavities Spool for service port valves of type TBSD280.
Page 443 Outlet section U13B SAE20 SAE16 G ¾" SAE16 The standard outlet section U13B has three tank connection ports T2, T3 and T4. Port T3 is used for high pressure carry over function (HPCO) when plug S29 is installed in the S1 cavity (see example). Outlet selection U13B S1 Carry over plug...
Page 444 Outlet with working section US24L A-side SAE12 B-side SAE12 SAE06 SAE06 SAE16 The US24L is an outlet section with integrated spool section, T3 port for tank connection for both manual operation and remote control with external pilot pressure supply. High pressure carry over function is achieved with SU31 installed in port T3.
Page 445 Spool controls A-side The spool controls are designed in a modular system for a high degree of flexibility. The sections are basically symmetric but as standard machined either for left or right hand inlet with spool actuator on B-side and spool control on A-side. Spool control 9 9M1 Manual spring centered 3 pos.
Page 446 Solenoid valve for EHP – ER12 / 24 The solenoid valves are 3/2-way electrically operated pressure reducing valves used to provide controlled pilot pressure to operate valve spools. Functional principle: PWM (Pulse Width Modulation) 100 % Duty factor: Connection: DEUTSCH DT04* 100 Hz Recommended PMW frequency: Protection class:...
Page 447 Spools – main design parameters Generally the spools are divided in 3 different flow ranges. The position indicating regulated flow ranges is replaced by X. The position indicating pump flow is replaced by Y. The last three positions in the code are design parameters. In the table only the accessibility of different functions are shown.
Page 448 Service port valves Port relief valve TBD205 TBD205 is a differential area, direct acting relief valve, for ∆P (bar) the secondary circuit. It is adjustable and sealable. Setting range for TBD205: z 600-4,350 psi (40-300 bar) z Setting range step: 100 psi (7 bar) l/min Relief characteristics TBD205...
Page 449 Service port valves Anticavitation valve SB280 The anticavitation valve service to ensure that, in the event of a ∆P (bar) lower pressure in the cylinder port than in the tank, oil can be drawn from the system oil tank to the consumer. l/min Anticavitation characteristics TBSD280 and SB280...
Page 451 Valve Series Coordinate ID Spare parts list DX-6 Table of Contents Typical valve specification Section assembly coordinate IDs Inlets AA00) I1 3B I23B Outlets AF00) U1 3L US24L Transition Block EH, Manual) Relief valves BN00,CE,CP) TB1 2 TBD201 TBSD205 P204 El.
Page 452: Typical Valve Specification
Valve Series Coordinate ID Spare parts list DX-6 Typical valve build specification Page | 2 MHD-200005...
Page 453: Section Assembly Coordinate Ids
Valve Series Coordinate ID Spare parts list DX-6 Section Assembly Coordinate IDs *See specific Coordinate IDs in this document for service details. Page | 3 MHD-200005...
Page 454: I1 3B
Valve Series Coordinate ID Spare parts list DX-6 AA00 I1 3B *Relief valve not included, order separately Page | 4 MHD-200005...
Page 455: I23B
Valve Series Coordinate ID Spare parts list DX-6 AA00 I23B *Relief valve not included, order separately Page | 5 MHD-200005...
Page 456: U1 3L
Valve Series Coordinate ID Spare parts list DX-6 AF00 U1 3L Page | 6 MHD-200005...
Page 457: Us24L
Valve Series Coordinate ID Spare parts list DX-6 AF00 US24L *Accessories not included, order separately Part No Description 690001 4203 Outlet and working section, With cavity for high pressure carryover nipple. T3 SAE-1 6, Pp&Tp SAE-6. Page | 7 MHD-200005...
Page 458: Transition Block Eh, Manual)
Valve Series Coordinate ID Spare parts list DX-6 AF00 Transition Block *Supplied as internal pilot, external drain configuration Part No Description 29001 84 Plug for internal drain 261 0220 Cavity plug for external pilot -To convert to internal drain, remove plug Y and remove isolation plug inside port, replace Y plug in port;...
Page 459: Tb1 2
Valve Series Coordinate ID Spare parts list DX-6 BN00 TB1 2 *For use with I1 3B 29001 39) inlet TB1 2-S-XXXX *Order relief valve by model code: where XXXX is the desired pressure setting from 0500 to 5000 PSI, set in 50 PSI increments. -This is an adjustable pilot relief valve with optional factory setting Part No Description...
Page 460: Tbd201 1
Valve Series Coordinate ID Spare parts list DX-6 BN00 TBD201 *For use with I23B 2900686) inlet TBD201 -S-XXXX *Order relief valve by model code: where XXXX is the desired pressure setting from 0500 to 5000 PSI, set in 50 PSI increments. -See table above to determine full adjustability range of factory set valve.
Page 461: Tbsd205
Valve Series Coordinate ID Spare parts list DX-6 CE,CP TBSD205 TBSD205-S-XXXX *Order relief valve by model code: where XXXX is the desired pressure setting from 0500 to 5000 PSI, set in 50 PSI increments. -See table above to determine full adjustability range of factory set valve. Part No Description 351 5233...
Page 462: P204
Valve Series Coordinate ID Spare parts list DX-6 CE,CP P204 Description Part No 6900002245 Plug replacing TBSD205 351 5233 Replacement seal kit for TBSD205/P204 Page | 1 2 MHD-200005...
Page 463 Valve Series Coordinate ID Spare parts list DX-6 AA08 WS08Y-01 M *For use with I1 3B 29001 39) inlet *Available in 1 2VDC or 24VDC Part No Description Model Code WS08Y-01 M-1 2DG 301 9408 2-way, normally open, solenoid type cartridge valve. intended for emergncy stop and for pressure/heat reduction.
Page 464: Eu1 2, Eu24
Valve Series Coordinate ID Spare parts list DX-6 AA08 EU1 2, EU24 *For use with I23B 2900686) inlet *Available in 1 2VDC or 24VDC Part No Description 690001 401 5 2-way, normally open, solenoid type cartridge valve, for unloading function. Rated 1 2VDC 690001 401 6 2-way, normally open, solenoid type cartridge valve, for unloading function.
Page 465: Pe20
Valve Series Coordinate ID Spare parts list DX-6 AA08 PE20 *For use with I1 3B 29001 39) inlet Part No Description 6900002241 Plug replacing electric control solenoid valve *No seal kit avaliable for this plug Page | 1 5 MHD-200005...
Page 466: Pe21
Valve Series Coordinate ID Spare parts list DX-6 AA08 PE21 *For use with I23B 2900686) inlet Part No Description 690001 2644 Plug replacing electric control solenoid valve 3052427 Replacement seal kit for EU1 2/PE21 Page | 1 6 MHD-200005...
Page 467: Pm02
Valve Series Coordinate ID Spare parts list DX-6 FR05 PM02 Part No Description 6900002256 Plug disconnecting parallel passage pump flow passage. 6900005871 Replacement seal for PM02 Page | 1 7 MHD-200005...
Page 468: Metering Orifice Aa1 2) 1
Valve Series Coordinate ID Spare parts list DX-6 AA1 2 Metering orifice Model Code Part No Description PF08 2900476 Metering orifice for center channel flow, 2 gpm, in combination with FK29 and pump flow 25 gpm; green. PF1 6 2900475 Metering orifice for center channel flow, 4 gpm, in combination with FK29 and pump flow 25 gpm;...
Page 469 Valve Series Coordinate ID Spare parts list DX-6 AA28 TRA63 Replacement seal kit includes: x1 pc 8.3x2.4 x1 pc 1 0.3x2.4 x1 pc 1 5.4x2.1 x1 pc 11 .0x1 5.0x1 .0 backup x1 pc 9.0x1 3.0x1 .0 backup Part No Description 6900000064 Pressure reducing valve, pilot pressure 350 psi...
Page 470: P63
Valve Series Coordinate ID Spare parts list DX-6 AA28 Replacement seal kit includes: x1 pc 8.3x2.4 x1 pc 1 0.3x2.4 x1 pc 1 5.4x2.1 x1 pc 11 .0x1 5.0x1 .0 backup x1 pc 9.0x1 3.0x1 .0 backup Part No Description 3522640 Plug replacing pressure reducing valve.
Page 471: Bup1 4
Valve Series Coordinate ID Spare parts list DX-6 AF04,AF06 BUP1 4 Part No Description 3522640 Back-up unit. Opening pressure 1 45 psi; designed for 0-50 gpm. In coordinate AF04 back-up pressure for pilot supply. In coordinate AF06 back-up pressure for anticavitation function. Page | 21 MHD-200005...
Page 472: Spools Bh)
Valve Series Coordinate ID Spare parts list DX-6 Spools Page | 22 MHD-200005...
Page 473: Obsolete Spools Bh)
Valve Series Coordinate ID Spare parts list DX-6 Obsolete Spools *Previously used in S23L 29001 44) body Page | 23 MHD-200005...
Page 474: Msk1 90
Valve Series Coordinate ID Spare parts list DX-6 LEVER MSK1 90 Part No Description 3550295 Complete hand lever for hexagon shaft on M1 , H2M1 and EHM1 00 spool controls. Page | 24 MHD-200005...
Page 475: Mv245, Mh245, Mv1 45
Valve Series Coordinate ID Spare parts list DX-6 LEVER MV245, MH245, MV1 45 Part No Description 2092029 Lever for use in combination with bracket M03; includes 1 lever, 1 ball knob, 2 pins and 4 e-clips; lever is vertical and 9.5 2092591 Lever for use in combination with bracket M03;...
Page 476 Valve Series Coordinate ID Spare parts list DX-6 *Hand lever sold separately *To install, rotate hexagon shaft fully inwards, towards the valve body, then move assembly over sawtooth installed on spool end, allowing sawtooth to engage gear wheel and rotate until fully engaged. Part No Description 29001 50...
Page 477: M03
Valve Series Coordinate ID Spare parts list DX-6 *Hand lever sold separately Part No Description 690001 2776 Manual actuator for spools with open ends. To be used with 3-position spools, to be used with 9M01 ; lever to be order as separate item. Page | 27 MHD-200005...
Page 478 Valve Series Coordinate ID Spare parts list DX-6 Part No Description 29001 23 Hydraulically operated spool actuator for 3-positional spools; Ports marked x and y are SAE-4, pressure in x moves spool position II (out) and pressure in y moves spool position III (in). Control pressure 80-250 psi;...
Page 479: H2M1
Valve Series Coordinate ID Spare parts list DX-6 H2M1 *Hand lever sold separately *To install, rotate hexagon shaft fully inwards, towards the valve body, then move assembly over sawtooth installed on spool end, allowing sawtooth to engage gear wheel and rotate until fully engaged. Description Part No 29001 24...
Page 480: Eh1 00
Valve Series Coordinate ID Spare parts list DX-6 EH1 00 *Solenoids sold separately Description Part No 290011 6 Electro-hydraulic spool control for 3-position spool. Ports marked x and y are solenoid cavities, pressure in x moves spool position II (out) and pressure in y moves spool position III (in).
Page 481: Ehm1 00
Valve Series Coordinate ID Spare parts list DX-6 EHM1 00 *Solenoids sold separately *Hand lever sold separately *To install, rotate hexagon shaft fully inwards, towards the valve body, then move assembly over sawtooth installed on spool end, allowing sawtooth to engage gear wheel and rotate until fully engaged. Description Part No 290011 5...
Page 482: 9M1
Valve Series Coordinate ID Spare parts list DX-6 Part No Description 29001 49 Spool control, manual for 3-position spools. Closed cap for wet spool ends, to be used with M1 . Page | 32 MHD-200005...
Page 483: 9M01
Valve Series Coordinate ID Spare parts list DX-6 9M01 Part No Description 367761 4 Spool control, manual for 3-position spools with open ends. To be used with M09. Page | 33 MHD-200005...
Page 484: 9R1
Valve Series Coordinate ID Spare parts list DX-6 Part No Description 2900252 Spool control, 3-position, for proportional pressure control. Control pressure 80 - 250 psi; max supplied pressure 725 psi. To be used with H2, H2M1 , EH1 00 and EHM1 00 Page | 34 MHD-200005...
Page 485: Solenoids
Valve Series Coordinate ID Spare parts list DX-6 Replacement seal kit includes: x1 pc 1 4.1 x2.4 x1 pc 6.5x1 .5 x1 pc 8.5x1 .5 Part No Description 2900563 Replacment solenoid 1 2VDC, deutsch connector* 2900564 Replacement solenoid 24 VDC, deutsch connector* 2900661 Replacement seal kit for solenoids *includes mounting screws...
Page 486: Mb29
Valve Series Coordinate ID Spare parts list DX-6 MB29 Part No Description 29001 48 Load check valve 690000241 6 Replacement seal for MB29 load check Page | 36 MHD-200005...
Page 487: Mf29
Valve Series Coordinate ID Spare parts list DX-6 MF29 Replacement seal kit includes: x1 pc 7.3x2.4 x1 pc 1 7.3x2.4 x1 pc 1 2.0x8.0x1 .3 backup Part No Description 290011 4 Load check valve with adjustable flow limitation 2901 894 Replacement seal kit for MF29 load check Page | 37 MHD-200005...
Page 488: Mp29
Valve Series Coordinate ID Spare parts list DX-6 MP29 Part No Description 29001 48 Cavity plug when load check function is not needed 690000241 6 Replacement seal for MP29 plug Page | 38 MHD-200005...
Page 489: Ps29
Valve Series Coordinate ID Spare parts list DX-6 FR05 PS29 *For use with U1 3L 29001 43) outlet Part No Description 290011 7 Carry over plug Page | 39 MHD-200005...
Page 490: Su31
Valve Series Coordinate ID Spare parts list DX-6 FR05 SU31 *For use with US24L 690001 4203) outlet Replacement seal kit includes: x1 pc 29.3x2.3 x1 pc 23.47x2.62 x1 pc 23.8x28.0x1 .3 backup Part No Description 690001 4205 Carry over plug, inner thread SAE-1 2 2901 895 Replacement seal kit for SU31 Page | 40...
Page 491: Pms6
Valve Series Coordinate ID Spare parts list DX-6 PMS6 *For use with U1 3L 29001 43) outlet Part No Description 2900253 Set screw, isolates pilot and main return oil flow. Page | 41 MHD-200005...
Page 492: Ssk
Valve Series Coordinate ID Spare parts list DX-6 Inlet Interface • Seal interface on inlet body includes (4) blanks for 5.28x1 .78 seals; install (2x) seals per notation • Note: seals align with corresponding pilot holes on the adjacent section Kit includes: x3 pc 29.2x3.0 x2 pc 22.2x3.0...
Page 493: Tie Rod Kits Al00)
Valve Series Coordinate ID Spare parts list DX-6 AL00 Tie Rod Kits Page | 43 MHD-200005...
Page 494: Solenoid Connectors
Valve Series Coordinate ID Spare parts list DX-6 Solenoid Connectors Kit includes: x1 pc Housing Part No x2 pc Contects x2 pc Wire seals 2095209 x1 pc Wire boot Description Replacement connector kit for AMP Junior Timer style solenoids, use 1 6 AWG TFFN wire *see MHD-700003 for full assembly instructions Kit includes: Part No...
Page 495: Relief Valve Field Service Guide
Valve Series Coordinate ID Spare parts list DX-6 Relief Valve Field Service Guide Page | 45 MHD-200000...
Page 496: General Troubleshooting Guide
Valve Series Coordinate ID Spare parts list DX-6 General Troubleshooting Guide Page | 46 MHD-200000...
Page 497 Valve Series Coordinate ID Spare parts list DX-6 General Troubleshooting Guide Page | 47 MHD-200000...
Page 498 Valve Series Coordinate ID Spare parts list DX-6 General Troubleshooting Guide Page | 48 MHD-200000...
Page 499 P280 FK29 2500 PSI TRA63 I13B S24L S24L S24L S24L U13L Hydac Mobile Hydraulics Div 1660 Enterprise Pkwy. Suite E Wooster, Ohio 44691 Description : Customer DX-604 ACE BROTHERS EQUIP. 2903625 Date: 08.10.2018 Designed by: Rhamey, Scott U:\Customers\HydroTech\Ferguson\18-17875 Brothers Equip\MHD-500443.vsdx...
Page 500 Page: Bill of Material Report TULSA WINCH, INC. Date: 8/28/2019 Single Level Time: 9:19:55 am Type Find Num Part Number Revision Description Qty/Parent Required Qty H75-SLRFXDX, W/CABLE PACKER 80897 1.00 40309 HOUSING, GEAR, M75 1.00 1.00 PC 40414 WORM, SL, H75 1.00 1.00 PC 20770...
Page 501 Page: Bill of Material Report TULSA WINCH, INC. Date: 8/28/2019 Single Level Time: 9:19:55 am Type Find Num Part Number Revision Description Qty/Parent Required Qty 40424 Gasket - C4 - 05.81 - 00.031 1.00 1.00 PC 4102-TW BUSHING & BREATHER KIT,1/2 1.00 1.00 PC 30203...
Page 502 REV. DESCRIPTION DATE DRAWN APPD. ER NO. CONVERTED TO SOLIDWORKS AND ITEM#13 BALL BEARING (20319) CHANGED TO 04/17/2019 17-1182 ANGULAR CONTACT BEARING (20620) SECTION A-A NOTES: 1. FILL WITH EP-140 OIL.(5 QTS) 2. PRIME WITH TWI PRIME SPEC 709171 (BLACK PRIMER) Unless Otherwise Specified Imperial (in) Jenks...
Page 503 REV. DESCRIPTION DATE DRAWN APPD. ER NO. CONVERTED TO SOLIDWORKS AND BALL BEARING (20319) CHANGED TO 04/17/2019 17-1182 ANGULAR CONTACT BEARING (20620) 20.00 25.77 5.00 10.00 GREASE GREASE ZERK ZERK 6.00 19.50 15.50 11.00 2.00 4.00 4.00 23.286 8.97 5.27 10.64 2.000 OIL LEVEL...
Page 504 Installation, Operating & Maintenance Manual Worm Gear Winch This manual MUST be kept with the winch at all times. New winch operators MUST read and understand the contents fully.
Page 505 WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH!  Do not use to lift or move people. If your task involves moving or lifting people, you must use the proper equipment, not this winch. ...
Page 506 INTRODUCTION Thank you for purchasing a new Tulsa Winch. We are proud of our products and are certain that they will perform your winch tasks properly. However, we do ask that you take a few minutes to read and thoroughly understand this booklet.
Page 507: General Operations
GENERAL OPERATIONS Be sure to read all safety instructions thoroughly. It is important that each operator is aware of the consequences of misuse or poor operating practices of this winch. Tulsa Winch products are not to be used to lift, hoist, or move people.
Page 508: Winch Break In
WINCH BREAK IN Winches, like any other kind of machinery, require a “break-in” to perform well and to maximize their life. The following guidelines should be used in the break-in of Tulsa Winches. Use extreme care when first spooling cable onto the winch.
Page 509: Winch Operation
WINCH OPERATION To familiarize yourself with the winch, run it for a few minutes to understand the controls and the “feel” of the winch. Pay particular attention to the controls and how they operate. If the winch has air controls on the brake or clutch, or both, operate them to see how they work and the direction of activation of the controls.
Page 510: Using A Snatch Block
USING A SNATCH BLOCK By using a snatch block you have effectively cut the load on the winch in half. A snatch block should be used any time you have a concern about the ability of the winch or cable to move a load. The following illustration shows one way to rig such a block CABLE CONSIDERATIONS As the number of layers of cable on a winch increases, the...
Page 511 CABLE CONSIDERATIONS (Continued) Winch Model Cable Size 7/16” 1138 or RN10W 7/16” 1000 7/16” 1200 1/2” 10 or RN15W 1/2” 1/2” 5/8” 5/8” 5/8” 23 or RN20W 5/8” 3/4” 34 or RN30W 3/4” 64 or RN45W 7/8” 70 or RN65W 1”...
Page 512: The Importance Of A Proper Fleet Angle
THE IMPORTANCE OF A PROPER FLEET ANGLE Maintaining the proper fleet angle is important to the success of your winching operation, the life of your winch and the life of the cable you are using. The fleet angle can best be described by the following illustration. Fleet Angle The fleet angle should be kept as small as possible to insure proper spooling and to maximize cable and winch...
Page 513: Cable Installation
CABLE INSTALLATION To install the cable wedge anchor, first consult the wire rope manufacturer for recommendations on how to prepare the end of the wire rope. Thread the prepared end of wire rope through the smaller side of the opening of the cable drum wedge pocket.
Page 514: Winch Mounting
WINCH MOUNTING You must make sure that your winch is securely mounted in order for it to function properly and to insure safe operation. The mount must be flat to insure proper alignment between the gearbox side, the drum, and the clutch A rule of thumb to use when selecting capscrews to mount the winch is to use the same size and number of...
Page 515 WINCH MOUNTING (Continued) Model Max. Span No. of Size (Inches) Capscrews Capscrews 1/2" 1138 or RN10W 1/2" 1000 1/2" 1200 1/2" 10 or RN15W 3/4" 3/4" 3/4" 3/4" 3/4" 23 or RN20W 3/4" 1” 34 or RN30W 1” 64 or RN45W 8 or 12 1 1/8”...
Page 516: Winch Maintenance
WINCH MAINTENANCE A winch, like any other type of machinery, needs to have regular maintenance if it is to perform properly, give lasting value, and provide safe winching. Good maintenance consists of two parts, a daily inspection and a periodic servicing.
Page 517 WINCH MAINTENANCE (Continued) Bi-Annually Every six months, the gearbox should be drained and filled with new, clean gear lubricant. All Tulsa worm gear winches are filled at the factory with EP140 gear lube, which is ideal for most working conditions. If the ambient temperatures where your winch will be working will not exceed 30 degrees F., you can use EP90;...
Page 518: Automatic Worm Brakes
AUTOMATIC WORM BRAKES Most Tulsa winches are equipped with an automatic worm brake to hold suspended loads. If your winch is not equipped with one, it is intended for pulling loads only. If you wish to lift and suspend loads with your winch, it can be retrofitted with an automatic worm brake.
Page 519 AUTOMATIC WORM BRAKES (Continued) The following illustration shows the end cover of the typical shoe brake and how to adjust it Adjustable Shoe Brake To tighten the brake, loosen the two capscrews in the slotted holes and rotate the brake in the direction shown. If the brake on a Model 10 through 34 needs to be reversed, remove those same two capscrews, rotate the cam 60 degrees in the loosening direction, and reinstall the...
Page 520 Some versions of the Models 10 through 80 are equipped with a non-adjustable multiple disc oil brake. These winches can be identified by the warning on the cover Non-Adjustable Multi Disk Oil Brake Caution During Removal! Spring Loaded Cover These brakes require no regular adjustment. The direction of braking for all multiple disc brakes can be changed by removing the cam clutch, turning it over, and re-installing it.
Page 521 BRAKE ADJUSTMENT In general, worm brakes on Tulsa winches should only be adjusted enough to hold the load you are currently working with. Over adjustment will result in excessive heat generation and brake wear. The most positive way to insure proper brake adjustment is to lift a test load just barely off the ground, jog the winch out, and see if the brake holds.
Page 522: Drum Clutch Position Indicator
DRUM CLUTCH POSITION INDICATOR The clutch position indicator operates in a normally open position. When properly installed, as pictured in the circuit a warning light or horn will indicate when the drum clutch is disengaged Sel-0038.docx Rev2...
Page 523: Winch Model Codes
WINCH MODEL CODES RN100 W M L F O M X Basic Model Gear Type W=Worm P=Planetary Drive Type H=Hydraulic M=Mechanical Gearbox Position (viewed from rear of truck) L=Left R=Right Input Shaft Location (viewed from rear of truck) F=Front R=Rear X=Does not apply Cable Spooling (viewed from rear of truck)
Page 524 WINCH MODEL CODES H 23 – S L R F O D CL Optional U-Utility G-Speed Reducer C-Capstan Drive H-Hydraulic Basic Model No. of Worm Starts S-Single D-Double T-Triple Worm Angle L=Left R=Right Gearbox Location (viewed from rear of truck) L=Left R=Right Input Shaft Location...
Page 525 ALL Tulsa Winches have the serial number, and assembly number stamped both on the identification tag and on the housing. Please take a few minutes to record these numbers for future use. The assembly number will be required when ordering parts.
Page 526: Tulsa Winch Limited Warranty
TULSA WINCH LIMITED WARRANTY Effective 1/1/2005 Supersedes All Prior Warranties Seller warrants that each article sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in material and workmanship during normal and ordinary use and service (the "Warranty"). Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part thereof which has proven to be defective, or to refund the purchase price of such article or part thereof.

This manual is also suitable for:

Art-60-36 Art-60-25 Art-60-25-bt Art-60-40

Ace ART-60 Series Operating Instructions Manual

Quick Links

Chapters

Related Manuals for Ace ART-60 Series

Summary of Contents for Ace ART-60 Series

This manual is also suitable for:

Table of Contents