800 Series Service Manual - Standard
Contents
1. TABLE 6 SPIGOT WEAR LIMITS ITEM PART NO WEAR LIMIT FOR WEAR LIMIT FOR STANDARD BUSHING OVERSIZE BUSHING 1 800021 Spigot 2 2 530 800010 2 530 Max Min Bushing 800009 2 500 Min Bushing 7 800200 Spigot 1 2 350 22128 2 350 Max Min Bushing 22129 2 300 Min Bushing 4 700096 Spigot 0 2 350 22128 2 350 Max Min Bushing 22129 2 320 Min Bushing SERVICE BUSHING WEAR MEASUREMENT To determine wear take two measurements 90 deg apart A A and B B as shown or measure over visible wear area The smaller of the two dimensions is to be taken as the wear limit See Table 6 for values NOTE If spigot is below min dimension shown in Oversize Table contact Chalmers for guidelines AS 1 Joint 800 Series Tandem Truck 40 000 Ibs NM Ni gt gt a 2 Joint 800 Series Tandem Truck 46 000 to 58 000 Ibs Capacity Capacity after Jan 1 93 f A NG DH 0 Joint 800 Series Tandem Truck 40 000 Ibs Capacity before Jan 1 93 34 APPENDIX A SERVICE BULLETIN RE PART NO 260002 IMPORTANT Inspect Part No 260002 when rebushing installing new hardware or when repeated loosening of the hardware occurs SURFACE A 003 MAX WEAR OR INDENT DEPTH IN AREA A To Inspect Remove cap from joint remove all dirt rust oil and grease from bolt head contact area surface A Inspect surface A2. The surface must be flat to a diameter 1 25 min No wear or indent deeper than 005 is allowed in this area IF THE CAP DOES NOT MEET THE ABOVE GUIDELINES IT MUST BE REPLACED FAILURE TO DO SO MAY CAUSE SEPARTION OF THE JOINT LEADING TO LOSS OF CONTROL OF THE VEHICLE 35 APPENDIX B TECHNICAL SALES BULLETIN No 15 Restrictor Can Available and Application Chart B TRUCK SUSPENSION MODEL Restrictor Part A B C Usage by Standard Comments Can No Model Capacity Optional 15 373015 4 38 11 19 0 125 800 XX Series Std Tandem Axle 36 000 Ibs only 28 373028 4 44 12 63 0 173 800 XX Series Std Tandem Axle All Capacities 29 373029 5 17 11 64 0 173 800 XX Series Optional Tandem Axle All Capacities High C of G i e concrete mixer logger Edited for 800 Series 10 11 36 APPENDIX C ENGINEERING BULLETIN 8904 WEAR PLATE INSTALLATION Chalmers Suspension Walking Beam Read all safety notes in Section 2 0 of Engineering Bulletin 8905 Prior to any installation work support the vehicle on stands apply brakes and block wheels Prior to any welding read all general notes and welding processes in Sections 3 0 4 0 5 0 amp 6 0 of Engineering Bulletin 8905 Remove both beams from the suspension clean and inspect Inspect beams as per Section 7 5 of Engineering Bullet
3. 800 SERIES SERVICE MANUAL 40 000 58 000 LB PART EDOC001 CHALMERS SUSPENSIONS INTERNATIONAL INC 6400 NORTHAM DRIVE MISSISSAUGA ONTARIO CANADA L4V 1J1 905 362 6400 VOICE 905 362 6401 FAX OUR EDGE IS OUR PRODUCT 1 0 2 0 3 0 4 0 5 0 6 0 Contents Page No GENERAL 1 INTRODUCTION TO THE SUSPENSION 2 2 1 SUSPENSION PART cnn 2 SERVICE INSPECTION REQUIREMENT S 4 GUIDELINE TO THE INSPECTION AND REPLACEMENT OF SERVICE 6 4 1 EAASHEENBRSLEELAEO debe SAD 7 4 2 TORQUE ROD BUSHING INSPECTION 4 8 4 3 TORQUE ROD BUSHING REPLACEMENT 10 4 4 RESTRICTOR CAN 14 4 5 RESTRICTOR CAN REPLACEMBNT eee 14 4 6 SPIGOT CAP INSPECTION 0 cece ec cee e cece ee eeeees 16 4 7 SPIGOT CAP REPLACEMENT 17 4 8 SHOCK ABSORBER INSPECTION 17 4 9 SHOCK ABSORBER REPLACEMENT 18 4 10 WALKING BEAM 21 4 11 WALKING BEAM REPAIR REPLACEMENT 22 4 12 RUBBER SPRING 24 4 13 RUBBER SPRING 25 AXLE ccenecceeneceeuneeers 26 5 1 AXLE bre DER 27 5 2 AXLE ALIGNMENT ADJUSTMENTS 29 100 eeeeeeeees 31 1 0 APPENDIX lcd APPENDIX Dr APPENDIX Pee APPENDIX TE cir EA A A E AS AOS 34 35 36 38 41 43 1 0 GENERAL IN
4. NUMBER 2 JOINT ASSEMBLY 260002 Spigot Cap 0 Joint 6 22128 T Rod Bushing 0 amp 1 Joint 6A 22129 T Rod Bushing Oversize 0 amp 1 Joint 800200 Spigot Base 1 Joint za 800201 Spigot Cap 1 Joint Service Bushing 2 Joint 800 Series Tandem Truck 46 58 000 Ibs Capacity NUMBER 1 JOINT 1 Joint ASSEMBLY 800 Series Tandem Truck 40 000 lbs Capacity as of Jan 01 93 0 Joint 800 Series Tandem Truck 40 000 Ibs Capacity prior to Jan 01 93 NUMBER 0 JOINT ASSEMBLY FIGURE 2 4 3 10 TORQUE ROD BUSHING REPLACEMENT Replacement of Chalmers Torque Rod Bushings may be achieved easily and quickly in any shop without the use of a press or special tools using the following steps as a guide STEP 1 If possible power wash the torque rod ends as a minimum the ends should be brushed with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Remove all drive axle brake or wind up loads by placing transmission in neutral and releasing the spring or driveline brakes STEP 3 Lift the rear of the vehicle Support the frame on stands so all weight is just taken off the suspension NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 4 Work on only one torqu
5. 4 3 Spigot Cap and or Fasteners Loose Re Bush and torque check to 135 ft lbs See Sections 4 2 4 3 amp Table 2 Adjustable Torque Rod Tube Pull Out or Back Off Eye Pinch Bolts Not Torqued Properly Replace torque rod and torque check pinch bolts See Table 2 Walking Beam Touching Triangular Frame Worn or Loose Upper Torque Rod Bushings Re Bush upper torque rods See Sections 4 2 amp 4 3 Premature Beam End Wear Wet Highly Abrasive Road Conditions Add wear pads to beam or replace beam See Sections 4 10 amp 4 11 Excessive Tire Wear Axles Out of Align Re Align See Sections 5 1 amp 5 2 Tire Pressure Check tire pressure and inflate to manufactures specification Excessive Axle Movement Worn Bushings Re Bush See Sections 4 2 amp 4 3 Adjustable Torque Rod Pull Out Replace torque rod and torque check pinch bolts See Table 2 Excessive Wheel Bounce or Hop Worn or Broken Shocks Replace shocks See Sections 4 8 amp 4 9 No Shocks Fitted Install shock kit Tire Pressure Check tire pressure balance and inflate to manufacturers specifications Excessive Vehicle Bounce Unladen Worn or Broken Shocks Replace shocks See Sections 4 4 amp 4 5 No Shocks Fitted Install shock kit 32 PROBLEM POSSIBLE CAUSE AND CORRECTION Vehicle Does Not Sit Level Broken or Missing Restrictor Can Replace both restrictor cans See
6. providing end retention to the joint Two sizes of torque joints are used in the Chalmers 800 Series Suspension The suspension capacity and spigot caps used are shown in the following Table 3 TABLE 3 JOINT SIZE CAPACITY SPIGOT CAP NO BUSHING O E M SERVICE AFTER JAN 93 40 000 Ibs 800201 22128 22129 1 2 46 000 Ibs 800055 800010 800009 58 000 Ibs BEFORE JAN 93 36 000 Ibs 260002 22129 0 40 000 Ibs Spare Part Only NOTE Torque Rod Joint 1 superseded Joint 0 on all 40 000 Ibs 800 Series Suspensions built starting January 1993 All 40 000 Ibs 800 Series Suspension built before January 1993 have 0 Joints and Spigot Cap 260002 Check for Part No on Spigot Cap See Fig 2 Spigot Caps 800201 and 260002 are not interchangeable See Fig 2 Visual inspection of the spigot caps should be done on a daily basis See Section 3 0 Service Inspection Requirements IMPORTANT If a missing cracked or broken spigot cap is detected it MUST be replaced immediately DO NOT operate the vehicle To do so may lead to consequent loss of vehicle control and personal injury IMPORTANT If a loose spigot cap is found retorque the 5 8 NC fasteners to 135 ft Ibs See Table 2 Should persistent loosening occur replace the 5 8 NC fastener as hard part wear is affecting the bolt seat See Table 2 and Appendix A Service Bulletin Re Part No 260002 4 7 4 8 17 SPIGOT CAP REPLACEMENT Replacement of the
7. 1 show that the axles are not within either the vehicle manufacturers specifications or the Chalmers recommended guidelines an axle adjustment will be required This may be done without the use of any special tools using the following steps as a guide STEP 1 If the vehicle has been moved after measurement then the bushings MUST be neutralized and if a tape measurement is to be used reference points marked See Section 5 1 Steps 1 through 4 STEP 2 Working on the axle to be adjusted and on ONLY ONE torque rod at a time loosen the lower torque rod eye pinch bolts both ends See Fig 11 NOTE If the pinch bolt fasteners are badly corroded or damaged replace with NEW hardware STEP 3 Attach a pipe wrench to the torque rod tube A chain type wrench preferred Rotate this tube to either lengthen or shorten the torque rod Continue this process until the axle is within alignment specification referred to in Section 5 1 Steps 3 or 4 NOTE If difficulty is encountered rotating the tube the threaded ends may have become corroded Apply a quality penetrating oil to the threads If difficulty is still encountered wedges may be driven between the eye lugs to remove the clamp effect Before retightening the torque rod pinch bolts visually check the rubber bushings They should appear even around the eye with NO distortion If distortion is seen neutralize the bushing and re measure STEP 4 Tighten and torque the eye pi
8. 3 8 NC fasteners holding the lower spring plate to the beam Discard the fasteners Pull the lower spring plate spring and restrictor can as one assembly outward off the beam See Fig 5 NOTE On 54 0 spread suspensions it may be necessary to remove either the front or rear tires to allow spring assembly removal 5 0 26 STEP 4 Separate the restrictor can spring and lower spring plate Discard the rubber spring Using a wire brush or scraper clean all rust scale and road dirt accumulations from the spring plate Clean out the centre vent holes in the beam and lower spring See Fig 5 Inspect the lower spring plate for visual cracks If cracked replace Contact Chalmers for details STEP 5 Place the new spring on the lower spring plate inserting the spring dowel into the centre spring hole Place the restrictor can over the spring Make sure the can centre locator is in the centre spring hole See Fig 5 STEP 6 Lift and place as one assembly the lower spring plate spring and restrictor can onto the beam Line up the two 3 8 fastener holes STEP 7 Install and tighten the new 3 8 NC spring plate fasteners Torque to 35 ft Ibs See Table 2 AXLE ALIGNMENT The 800 Series Tandem Suspension uses four torque rods for each axle These torque rods are the ONLY parts in the suspension that affect the location or alignment of each axle The four 2 per axle top vee torque rods set the axle spread side
9. International Inc walking beam centre reinforcement compression gusset attachment fillet welds Safety 2 1 2 2 2 3 2 4 The following safety instructions must be read and followed Failure to do so could lead to serious injury or possible loss of life Prior to any work commencing on the vehicle the cargo compartments and delivery systems must contain a non explosive and non toxic atmosphere Any stands or jacks used to support or lift the vehicle must be of sufficient capacity to do so with adequate safety margins Do not work under the vehicle when supported by jacks only All welding equipment and power tools must be used in and according to the manufacturer s safety and operating instructions General Instructions 3 1 3 2 3 3 3 4 3 5 MATERIAL CLEANING all material shall be free from loose scale slag oil rush and other foreign material JOINT PREPARATION joint surfaces shall be free from loose scale and rust Burned surfaces shall be smooth within 1 32 TACK WELD use appropriate size electrode and same type as specified below Employ corresponding weld data from chart below PREHEAT weld joint area as specified in 4 0 CLEAN all slag and spatter between passes Welding process 4 1 4 2 4 3 USE REVERSE POLARITY electrode positive WELDING SPEED shown is the ABSOLUTE MINIMUM DO NOT WELD SLOWER THICKNESS in between those specified on the chart use data from column of next s
10. Sections 4 4 amp 4 5 Damaged Spring Replace spring See Sections 4 12 amp 4 13 Damaged Walking Beam Replace walking beam See Sections 4 11 In a New Vehicle High Low Beam Installation Problem Replace incorrect beam Vehicle Unstable Rolls Requires High Stability Restrictor Can Use restrictor can 373029 Optional Replace both Broken or Missing Restrictor Can Replace both restrictor cans See Sections 4 4 amp 4 5 Damaged Spring Replace spring See Sections 4 12 amp 4 13 Vehicles Rides Excessively Hard Tire Pressure Check tire pressure and inflate to manufacturers specifications Damaged Spring Replace spring See Sections 4 12 amp 4 13 Insufficient Clearance Between Beam Stop and Beam Replace with correct length stop Broken or Missing Shocks Replace shock or install shock kit See Sections 4 8 amp 4 9 Vehicle Handles Poorly Tire Pressure Check tire pressure and inflate to manufacturers specification Axles Out of Align Re align See Sections 5 1 5 2 Worn Bushings Re bush See Sections 4 2 amp 4 3 Broken or Missing Shocks Replace shocks or install shock kit See Sections 4 8 amp 4 9 Broken or Missing Restrictor Can Replace both restrictor cans See Sections 4 4 amp 4 5 Damaged Spring Replace spring See Sections 4 12 amp 4 13 Insufficient Beam Stop Beam Clearance Replace with correct length stop 33
11. is just taken off the suspension NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 4 Remove the spring plate spring and restrictor can following Steps 3 and 4 in Section 4 5 STEP 5 Remove the upper and if necessary the lower torque rod from the rear most axle following Step 4 outlined in Section 4 3 NOTE Tag or mark each torque rod so as each rod may be replaced in the exact position it came off STEP 6 Roll the rear axle back so as the beam end is free of the saddle Raise the free end up and slide the beam back to remove from suspension STEP 7 Install the replacement or repaired beams by sliding the beam ends into the respective saddles on the front axle See Fig 9 Roll the rear axle forward and at the same time slide the rear beam ends into their respective saddles STEP 8 Replace the rear axle upper and lower torque rods following Step 9 through 11 in Section 4 3 STEP 9 Replace the spring plate spring and restrictor can following Step 6 in Section 4 5 STEP 10 Torque all fasteners to values shown in Table 2 IMPORTANT FAILURE TO CHECK TORQUE MAY LEAD TO FASTENER FAILURE AND CONSEQUENT LOSS OF VEHICLE CONTROL AND VOID WARRANTY 24 BEAM INSTALLATION FIGURE 9 4 12 RUBBER SPRING INSPECTION The Chalmers patented rubber spr
12. spigot caps may be achieved easily and quickly with no requirements to remove major parts from the vehicle or use special tools using the following steps as a guide STEP 1 If possible power wash the torque rod ends As a minimum the ends should be brushed with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Remove all drive axle brake or wind up loads by placing transmission in neutral and releasing the spring or driveline brakes NOTE On the axle tower pry off the tower plug cap to access the joint nuts Reinstall the cap when spigot cap replacement is finished STEP 3 Remove the 5 8 NC fasteners and pry off the spigot cap discard both STEP 4 Press the replacement spigot cap into the ends of the torque rod bushings STEP 5 Install and tighten new 5 8 NC torque rod joint fasteners Torque to 135 ft Ibs See Table 2 IMPORTANT Failure to check torque may lead to fastener failure and consequent loss of vehicle control and void warranty SHOCK ABSORBER INSPECTION Shock absorbers are provided on the 800 Series Suspension as an option to provide specific ride properties for different road conditions The 800 Series Suspension may be fitted with either beam mounted or axle mounted shock absorbers See Fig 6 and Fig 7 The replacement procedure is essentially the same for both types of shock absorbers NOTE ONLY ONE TYPE OF KIT SHOU
13. use other fasteners To do so may lead to fastener failure and consequent loss of vehicle control IMPORTANT FAILURE TO CHECK TORQUE MAY LEAD TO FASTENER FAILURE AND CONSEQUENT LOSS OF VEHICLE CONTROL TORQUE ROD BUSHING INSPECTION All 800 Series Suspensions incorporate rubber bushed torque rod joints that isolate the vehicle from axle braking and driving shocks To accommodate the full range of suspension capacities Chalmers has two sizes of bushing See Fig 2 for details Both bushings are similar and they both absorb axle shock by compression This compression may give a false impression of a worn bushing To reduce the chances of prematurely replacing a good bushing the following steps should be used when inspecting all Chalmers bushings STEP 1 If possible power wash the torque rod ends As a minimum the ends should be brushed with a hard bristle brush to remove road dirt accumulations so that the rubber bushing may be seen STEP 2 Chock the front tires to prevent the vehicle from moving Remove all drive axle brake or wind up loads by placing transmission in neutral releasing spring brakes or driveline brake STEP 3 USING HANDS ONLY attempt to move the torque rod ends checking for FREE play If free play is felt the bushing should be replaced If in doubt contact Chalmers NOTE DO NOT USE A PRY BAR OR LEVER to check for free play To do so may lead to premature bushing replacement SPIGOT JOINTS
14. 5 14 RESTRICTOR CAN INSPECTION The Chalmers spring system comprises of a rubber spring and an enclosing metal restrictor can The purpose of the restrictor can is to provide specific ride road handling characteristics and protection to the spring To accommodate the different road handling conditions that may be encountered Chalmers produces a number of different sized restrictor cans Refer to Appendix B Technical Sales Bulletin No 15 for application guidelines The free floating design of the Chalmers spring and beam requires that the restrictor can be free to move on the vehicle frame The restrictor can will wear or corrode over a period of time and will require replacement Carefully inspect the restrictor can for cracks or severe corrosion using the following steps as a guideline STEP 1 If possible power wash the restrictor can spring area As a minimum brush the area with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Lift the rear of the vehicle support the frame on stands so that all weight is just taken off the suspension NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Rotate the restrictor can completely around looking at the top and sides for visual cracks and signs of severe cor
15. DH 10 av Lz 92 NH DH 108 av 91 amp 091 UNNE SANS DH 10 av ar E HV OY L 22 z 1X36 008 12 5 HH 310048 02 gt MEINE E E als Ese 9 5 HH Ski 5 2 y Z ONTHST 008 300000 E IF dv 2 2 sag aed m mn WW coal Xd O0 1 3007 6 0081 89001 8 ENE Oy OS Wao ac 9 NW INN OOT E MWS val 2 ved WTW I 011419530 WALT FIGURE 1 3 0 SERVICE INSPECTION REQUIREMENTS The Chalmers 800 Series Suspension was designed to require minimum general maintenance The recommendations shown on the following chart are precautionary and are aimed at avoiding future problems 1000 Mile PART ACTION P D I 1600 KM DLY MTH YRLY All Hardware Check torque to values shown on Table 2 On the daily walk around Visually inspect for looseness Torque Rod Wear check See Section 4 2 for Bushing guidelines Visually inspect for tears or cracks Visually inspect for correct installation See Sections 4 2 amp 4 3 for guidelines Restrictor Visually inspect for wear or Can cracking Replace as required See Sections 4 4 amp 4 5 for guidelines Visually inspect for missing cans and cans not centered on spring On the daily walk around visually inspect for missing cracked broken or loose caps Replace as required or retorque See Se
16. E GR G flanged head Stover locknut The sizes of these systems have been specifically engineered for each of their positions and functions within the suspension See the following Table 1 for size and function TABLE 1 SIZE CAPACITY FUNCTIONS 7 8 Dia 46 000 Shock Absorber Option to Frame to Axle 58 000 3 4 Dia 40 000 Shock Absorber Option to Frame to Beam 58 000 5 8 Dia 40 000 ALL Torque Rod Joints amp to Torque Rod Eye Pinch Bolts 58 000 1 2 Dia 40 000 Torque Rod Eye Pinch Bolts 3 8 Dia 40 000 ALL Spring Plates to To Beams 58 000 Single pinch bolt style Double pinch bolt style For the safety and proper operation of the suspensions ALL FASTENERS MUST using a calibrated torque wrench be initially torqued and retorqued at 1000 miles 1600 km of service to the specific values shown on Table 2 4 2 TABLE 2 Torque Specifications For Bolts and Locknuts provided by Chalmers BOLT SIZE ASSEMBLY TORQUE FT LBS 3 8 35 1 2 65 5 8 135 3 4 170 7 8 170 Values for shock installation only For all other uses contact Chalmers Suspensions The above torques are recommended for Chalmers supplied hardware only and are NOT intended for hardware supplied by others NOTE Re torque must be done to both original and replacement fasteners IMPORTANT For fastener replacement use ONLY NEW CHALMERS approved fasteners DO NOT RE USE or
17. FORMATION This manual is to be used for the service of a Chalmers 800 Series Tandem Suspension and is intended to give guidance and recommendation for the care maintenance inspection and safe operation of the above suspension It is not a replacement for existing or future specific Pre Delivery Inspection P D I amp Preventative Maintenance Programs Before proceeding with any work on or with the suspension please read this manual completely to familiarize yourself with the maintenance and operation of the Chalmers Suspension TAKE SPECIAL NOTICE of procedures 1 1 through 1 6 that must be followed without exception when working on any procedures described in this manual 1 1 1 2 1 3 1 4 1 5 1 6 ALL CHALMERS FASTENERS must be torqued to the specific values shown in Table 2 and to the specific period shown on the Service Inspection Requirements Section 3 0 IMPORTANT Failure to check torque may lead to fastener failure and consequent loss of vehicle control and void warranty DO NOT USE ANY mineral based oils greases jellies or solvent soaps as a lubricant to aid in the assembly of the rubber bushed torque rods Use only quality rubber lubricants Failure to do so will void warranty DO NOT AT ANY TIME WORK AROUND OR UNDER A VEHICLE SUPPORTED ONLY ON LIFTING DEVICES THE VEHICLE MUST BE SECURELY CHOCKED AND SUPPORTED ON RIGID STANDS BEFORE WORK MAY COMMENCE ALL RELEVANT MACHINERY TOOL AND WORK PLACE SAFET
18. ITEM DESCRIPTION QTY R SHOCK BRACKET 2 ABSURBE H LOWER SHOCK BR LOWER SKU ARUENED WASHER 4 EX LOCKNUT STOVER 4 IMPRESSION SLEEVE 4 U ul Ek 70 NI CO 70 70 13 Co STAGGER WELD STOP WELD START NE POSITION PER PASS WELD STOP LF FIGURE 7 4 10 21 WALKING BEAM INSPECTION The Chalmers 800 Series Walking Beam is a key part of the load support and equalization system of the suspension It not only acts as a lower support and anchor point for the spring system but also provides the means to equally share the vehicle load to the axles To allow the high articulation that the 800 Series Suspension provides the walking beams MUST be free to move a total of 1 25 32mm fore and aft and 25 6 mm side to side when the vehicle is on level ground and loaded The walking beams have two wear points at the contact between the beam ends and axle saddles The rate of wear at these points will vary depending on the operating conditions axle loading and distance travelled Chalmers recommends inspecting the beams for end wear and cracks at the intervals shown in Section 3 0 Service Inspection Requirements Inspect the beam ends carefully looking for cracks and lower flange wear Cracks along welds may be repairable while cracks in or across the beam flanges require walk
19. LD BE FITTED TO THE SUSPENSION AN OVERLY STIFF RIDE MAY RESULT IF BOTH TYPES ARE USED ON THE SAME SUSPENSION Shock absorber No 665174 800781 or 800670 should be visually inspected on a monthly basis See Section 3 0 Service Inspection Requirements If a leaking road damaged badly corroded or shock with worn rubber end bushings is found it should be replaced as soon as possible NOTE Should a leaking or damaged shock absorber be found during vehicle operation the shock absorber should be removed immediately See Section 4 9 Shock Replacement Steps 1 to 5 or the vehicle may be driven SLOWLY to the nearest maintenance shop for either removal or replacement 18 4 9 SHOCK ABSORBER REPLACEMENT Refer to Fig 6 or Fig 7 to determine which shock absorber option is fitted to your vehicle For replacement of beam mounted shock absorber 665174 the following steps may be used as a guideline STEP 1 Chock the front tires and set the park brake to prevent the vehicle from moving STEP 2 Remove the top and bottom NC fasteners from the shock absorbers Pull the shock absorber from the bottom beam shock bracket Discard the fasteners and shock absorber STEP 3 Place the bottom eye of the replacement shock absorber into the beam bracket Refer to Fig 6 Install and tighten NEW 4 NC fasteners and hardened washers STEP 4 Adjust the shock absorber length so as the top eye lines up with the hole in the upper shock bracke
20. T1 electrode wire or equivalent COVER GAS use welding grade C02 cover gas Minimum Dew Point 50 or 95Ar 5C02 REGULAR SETTING 35 48 cu ft per hour Welding Sequence 5 1 5 2 PREHEAT to temperature as specified in Section 4 0 CHIP AND BRUSH all slag and spatter between passes grind out all defects 6 0 7 0 40 Inspection 6 1 Repair 7 1 FE 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 712 Visually inspect every completed row Prior to any repair work read all safety notes in Section 2 0 Prior to any installation support the vehicle on stands apply brakes and block wheels Prior to any welding read all general notes and welding process in Sections 3 0 4 0 5 0 and 6 0 Remove both beams from the suspension clean and inspect Inspect beam ends for cracks Only cracks in or through the web and stop plate may be repaired Any cracks that propagate into or through the flanges may not be repaired and the beam must be replaced See Fig 1 Check the bottom flange of the beams to be repaired If a beam does not have wear plates 700313 attached install them at this point See Technical Service Bulletin 8904 Grind or air arc out the crack areas Do not cut into the flanges Reweld beam end web and stop plates Build welds to 4 minimum 5 16 maximum fillets Clamp 3 8 x 1 7 8 x3 1 2 end web reinforcement plate to end web it may be necessary to
21. Y procedures and instructions must be followed without exception when working on any procedures described in this manual FAILURE TO ADHERE TO ANY SAFETY PROCEDURES OR INSTRUCTIONS MAY LEAD TO PERSONAL INJURY USE ONLY CHALMERS APPROVED REPLACEMENT PARTS Tests have shown alternate parts particularly torque rod bushings do not meet the performance expectations or engineering criteria established for the original products This has created extreme hard part wear or hardware failures with consequent loss of warranty and more important loss of vehicle control DO NOT operate the vehicle with the suspension in an over loaded condition Operating at a gross rear axle weight GRAW which exceeds the rated suspension capacity will lead to a suspension failure with consequent loss of vehicle control and void warranty 2 0 2 1 INTRODUCTION TO THE SUSPENSION The Chalmers 800 Series Rear Suspension is a walking beam type tandem axle suspension that uses hollow rubber springs instead of leaf springs or air bags Each hollow rubber spring is mounted between a frame rail plate and the centre front to rear of the steel walking beam A sawhorse bracket assembly is attached to the frame and provides mounting points for the lower torque rods that tie the axles to the frame The upper torque rods are fastened to brackets that bolt to the frame side rails and to tower assemblies that are welded to the top of the differential housings See Fig 1 T
22. ad If the gap is between 150 and 170 we recommend that the hardware be replaced and tightened to the correct torque specification If the gap is over 170 the bolts should be removed the pinch tabs separated using a chisel as a wedge and inspected for wear If a visible raised portion of the thread is evident in the area along the gap the tube has been worn and should be replaced If there is no evidence of wear replace the hardware and tighten to the correct torque specification All Chalmers fasteners must be final hand torqued to specifications on initial assembly Retorque is required after initial 1 000 miles 1 600 km in service Retorque within 12 months 42 APPENDIX E TECHNICAL SERVICE BULLETIN No 26 Part No Information Adjustable Torque Rod Tube 219 XX Length in 1 8 of an inch Length in inches Adjustable Torque Rod End RH Thread 22045 Adjustable Torque Rod End LH Thread 22046 Pinch Bolt 1 2 x 1 75 NC Gr8 Phos amp Oil Hardware 397 Locknut 1 2 NC GrG Hardware 393 Adjustable Torque Rod 216 XX X Lengthin 1 8 of an inch Length in inches FIGURE 1 FIGURE 2 43 APPENDIX F TECHNICAL SERVICE BULLETIN No 31 Subject 1 0 2 0 3 0 4 0 Repair and welding instructions for all Chalmers walking beam centre reinforcement compression gussets Scope This procedure shall be used when repairing and welding Chalmers Suspensions
23. ctions 4 6 amp 4 7 and Table 3 for guidelines 1000 Mile PART ACTION P D I 1600 KM DLY MTH YRLY OPTIONAL Visually inspect for leaks cylinder Shock damage or worn rubber end Absorber bushings Verify inspection if fitted schedules See Sections 4 8 amp 4 9 for guidelines Walking Inspect for wear and cracks See Beam Sections 4 10 amp 4 11 for guidelines Inspect for beam free float in axle saddles 1 25 32mm fore and aft 25 6mm side to side See Section 4 10 Axle Bracket Visually inspect for road damage or Triangular cracks Replace any damaged parts Frame as required Contact Chalmers for guidelines Rubber Visually inspect for chemical Spring damage deep tears and deformed springs Replace as required See sections 4 12 amp 4 13 for guidelines Visually inspect that the spring is sitting centrally on the spring plate and is seated down fully NOTICE The above chart was developed from Chalmers experience on parts subject to wear in normal service The wear rate is dependent on a number of factors such a load carried speed travelled roadbed conditions traffic density and number of stops NOTE IF THE OPERATOR OF THE VEHICLE IS IN ANY DOUBT ABOUT THE SAFETY OF THE SUSPENSION HE SHOULD NOT OPERATE THE VEHICLE AND SHOULD IMMEDIATELY SEEK QUALIFIED ADVICE 4 0 GUIDELINES TO THE INSPECTION AND REPLACEMENT OF SERVICE PARTS Recommended tools needed to carry out the w
24. e rod at a time Remove the 5 8 NC joint fasteners and spigot caps Discard the fasteners keep the spigot caps for inspection and cleaning Remove the torque rod from the spigots by prying at each end until it comes free of the spigots NOTE On the axle towers pry off the tower plug cap to access the joint nuts Keep the plug cap NOTE By completely removing and re fitting only one torque rod at a time the chance of torque rod mix up which could lead to re alignment of the suspension or loss of axle planning angle and consequent axle damage will be eliminated STEP 5 Place the torque rod on a bench or the floor with the bushing end facing up Remove the bushings by inserting the tip of a large screwdriver down between the bushing and the torque rod eye and prying out Discard the bushing STEP 6 Using a wire brush and or scraper clean all rust scale and rubber accumulations from the spigots torque rod eyes and spigot cap taking particular care to clean the inside taper of the spigots STEP 7 Inspect the torque rod eyes spigots and spigot caps for visual cracks and wear Should any of the following parts show visual cracks the part MUST be discarded and replaced Torque Rod and Eye Spigot Cap Should the spigot show visual cracks contact Chalmers for guidelines 11 For wear limits refer to Table 6 and Appendix A Service Bulletin Re Part No 260002 Chalmers allows for wear in its design by providi
25. ed torque rods To do so will lead to the premature failure of the bushing STEP 10 Push each end of the torque rod onto its relevant spigot Using a heavy soft faced mallet drive the toque rod onto the spigots For best results alternate end to end driving so as the torque rod bushings travel evenly over the spigots Continue driving until the bushing contacts the spigot bottom face 12 STEP 11 Press the spigot caps into the ends of the torque rod bushings secure the ends in place using new 5 8 NC fasteners Torque the 5 8 NC fasteners to 135 ft lbs See Table 2 IMPORTANT Failure to check torque may lead to fastener failure and consequent loss of vehicle control and void warranty Repeat Steps 1 through 11 for each torque rod to complete the suspension rebushing IMPORTANT USE ONLY NEW CHALMERS approved 5 8 NC fasteners for the joints DO NOT RE USE or use other fasteners To do so may lead to fastener failure and consequent loss of vehicle control and void warranty When finished rebushing check to see if the torque rods have been replaced as per Fig 4 The 46 000 to 58 000 108 Suspension upper rods must be oriented as shown in Fig 4 13 TORQUE ROD INSTALLATION UPPER TORQUE RODS 223157 Ba eae 40 000 LBS CAPACITY UPPER TORQUE RODS 800049 SUSPENSION 52 58 000 Ibs Capacity Tower 52 58 000 Ibs Capacity Tower 46 000 to 58 000 LBS CAPACITY SUSPENSION FIGURE 4 4 4 4
26. es Service and Maintenance Manual for guidelines 5 10 Check all bolts for correct torque See Section 4 1 Table 2 of the 800 Series Service and Maintenance manual for the correct torque specifications 5 11 Remove all stands and wheel blocks 45 AN p AN SN FIGURE 1 S IN WELD FILLET ONLY ALLOWED CRACKS IN WELD FILLET AND BEAM FLANGE OR WEB REPAIR IS NOT ALLOWED BEAM MUST BE REPLACED FIGURE 2 TE PART ND 800599 DO NOT WELD THE SIDE OF REINF PLATE E 1 4 MELO TOP AND BOTTOM OF REINE PLATE ONLY
27. grind the plate to obtain a good fit to end webs Tack weld in place Remove clamp and finish weld building weld to 4 minimum 5 16 maximum fillet Prime and repaint reworked areas Reinstall beams into suspensions Check all bolts for correct torque See Technical Service Bulletin 8018 Remove all stands and wheel blocks REPATRABLE END NN REPATRABLE END CRACKS CRACKS 41 APPENDIX E TECHNICAL SERVICE BULLETIN No 26 Subject Adjustable Torque Rod Part No 216XXX 0 Torque Rod End with Two Pinch Bolts IMPORTANT Failure to follow these instructions may result in separation of the torque rod during operation of the vehicle This may cause loss of control and vehicle crash The subject torque rods use two 2 pinch bolts to secure the torque rod end to the tube see Fig 1 These bolts must be tightened sequentially until proper torque value is obtained on both bolts It is recommended that 1 2 NC phosphate and oil grade 8 bolts and type G Stover nuts be used When Chalmers hardware is used the correct torque specification is 65 ft Ibs If the torque rods have been operated in a loose condition the threads may be worn such that clamp load cannot be restored by retorquing the bolts and nuts A method of determining if adequate clamp load has been maintained it so measure the gap at the torque rod as shown in Fig 2 If the gap is 150 or less the torque rod has sufficient clamping lo
28. h and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Rotate the spring completely around looking at the rubber spring below the restrictor can for deep cuts severe distortion and signs of chemical attack leaving the surface sticky or dry cracked If severe distortion is noticed contact Chalmers for details NOTICE Should a damaged spring be found during vehicle operation it may be driven SLOWLY to its maintenance shop for spring replacement Springs may be replaced in ones they do not require replacing in sets Failure to replace a damaged spring may lead to a hard ride or vehicle control problems with consequent vehicle damage RUBBER SPRING REPLACEMENT Replacement of Chalmers rubber springs may be achieved easily and quickly in any shop without the use of special tools using the following steps as a guide STEP 1 If possible power wash the restrictor can spring area As a minimum brush the area with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Lift the rear of the vehicle support the frame on stands so all weight is just taken off the suspension NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Remove the two
29. he 800 Series Rear Suspension allows a high degree of both parallel and diagonal articulation while maintaining wheel load equalization to within 3 The Chalmers suspension design separates the rear suspension s responsibility for supporting cushioning the load from that of locating guiding the axles The suspension is very light relative to its load carrying capacity and requires very little maintenance In fact there are no lubrication fittings since grease and oil are never needed The 800 Series is also available in three different axle spacings 54 inch 60 inch and 72 inch axle to axle The axle to axle spacing dimension is included as part of the suspension name e g Chalmers 854 Suspension or Chalmers 860 Suspension Shock absorbers are optional on all versions of the suspension and available in two styles beam mounted and axle housing mounted The rear suspension may be precision aligned by adjusting the length of the lower torque rods These rods have both left and right hand threads cut on the same tube so rotating the tube changes the effective length of the tube SUSPENSION PART NAMES Fig 1 shows an exploded view of a typical 800 Series Suspension Throughout this manual parts will be referred to by the names shown on this figure 097 UNO 82
30. in 8905 Clamp wear plate 700313 to bottom flange of beam Make sure plate is located centrally on flange and is a good profile fit to flange If required slightly grind to obtain this Tack weld plate to flange Tack on sides only Remove clamps Weld plate to flange as shown building weld to 1 4 minimum 5 16 maximum fillet CAUTION Do not weld at either end of the wear plate Prime and paint reworked area Reinstall beam into suspension Check all bolts for correct torque See Technical Service Bulletin 8018 Remove all stands and wheel blocks 37 WEAR PLATE NU 700313 WELD FROM HERE TO HERE ONLY WELD 1 4 MIN 3 16 MAX FILLET 1 0 2 0 3 0 4 0 38 APPENDIX D ENGINEERING BULLETIN 8905 Scope 1 1 Safety 2 1 22 23 2 4 REPAIR amp WELD INSTRUCTIONS Walking Beam Ends This procedure shall be used when repairing and welding Chalmers Suspensions International Inc walking beam ends The following safety instructions must be read and followed Failure to do so could lead to serious injury or possible loss of life Prior to any work commencing on the vehicle the cargo compartments and delivery systems must contain a non explosive and non toxic atmosphere Any stands or jacks used to support or lift the vehicle must be of sufficient capacity to do so with adequate safety margins Do not work under the vehicle when supported by jacks only All welding equipme
31. ing beam replacement See Fig 1 Appendix D Engineering Bulletin 8905 Lower flange wear requires the accurate measurement of lower beam flange thickness Measurements taken at the flange edges are not an accurate indication of beam wear see Fig 8 and may lead to unnecessary beam repair replacement Inspection of the beam ends may be done without removing any major parts using the following steps as a guideline STEP 1 If possible power wash the beam end As a minimum brush the area with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Lift the rear of the vehicle support the frame on stands so as all the weight is just taken off the suspension and the beam ends are off the saddles NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Manoeuvre the beam so as the wear area thickness on the bottom face may be determined using either a micrometer or a vernier calliper Measure the thickness at the wear area and a non worn area See Fig 8 The wear allowance is the difference between thicknesses and MUST not be any greater than 062 1 5 mm NOTE All measurements should be taken as a minimum of 1 2 from the beam flange edges to eliminate any edge wear that may have occurred If the beams show wear greate
32. ings used in the 800 Series Suspensions are manufactured to very exacting standards from a high quality natural rubber compound and in the vast majority of cases will last the life of the vehicle The rubber springs are factory matched to the capacity of the suspension to provide the best ride possible Three sizes are used in the 800 Series and are shown in Table 4 TABLE 4 CAPACTY SPRING SIZE PART NUMBER 36 000 Ibs 15 15015 40 000 Ibs to 20 15002 58 000 Ibs 65 000 Ibs to 26 15026 100 000 Ibs 4 13 25 Under normal operation the Chalmers rubber springs do not require periodic maintenance or replacement Minor scrubbing from the restrictor can and attachment fasteners is normal The springs also lose a little in overall height due to compression set This reduction in height occurs in the first few loads making an in service spring shorter than a new spring To reduce the chances of prematurely replacing a good spring the following steps should be used when inspecting all Chalmers rubber springs STEP 1 If possible power wash the restrictor can spring area As a minimum brush the area with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Lift the rear of the vehicle support the frame on stands so all the weight is just taken off the suspension NOTE All stands and lifting devices MUST be of sufficient strengt
33. l fully relaxed state Any compression remaining in the suspension will result in false readings or measurements and will lead to a misalignment being carried out To reduce the chances of this happening the following steps should be carried out prior to measurement and or alignment STEP 1 To remove any cornering compression either drive the vehicle back and forth a few times or if this is not possible lift the rear of the vehicle so all the load is just off the suspension Hold for a few minutes and then lower down Do not set park brake DO NOT AT ANY TIME WORK AROUND OR UNDER A VEHICLE SUPPORTED ONLY ON LIFTING DEVICES THE VEHICLE MUST BE SECURELY CHOCKED AND SUPPORTED ON RIGID STANDS BEFORE WORK MAY COMMENCE STEP 2 Chock the front tires to prevent the vehicle from moving Remove all drive axle loads by placing transmission in neutral and releasing the spring or driveline brakes STEP 3 Using a relevant alignment system and following all the manufacturers operating and safety instructions take measurements of the axle alignment Compare these to the vehicle manufacturers specification If none are available the following may be used as a guide For Hunter type equipment 08 deg Max thrust angle Rear axle for Bee Line type equipment 3 8 off centre 290 from target 1 4 off centre 190 from target The front rear and rear rear axle must TRAM to 1 16 side to side STEP 4 Use only when
34. maller weld size 5 0 6 0 7 0 5 3 5 4 5 5 5 6 5 7 5 8 44 4 4 MANUAL SHIELDED ARC PROCESS Thickness Ya 3 8 Type 7018 7018 Electrode Size 1 8 1 8 Amperage 130 130 Voltage 22 22 Weld Speed I P M 9 6 Preheat to room temperature 70 110 deg F Number of passes depends on type and size of joint Repair Prior to any repair work read all safety notes in Section 2 0 Prior to any repair work support the vehicle on stands apply brake and block front wheels Prior to any welding read all general notes and welding processes in Section 3 0 and 4 0 Remove both beams from the suspension see Section 4 11 of the 800 Series Service and Maintenance Manual for guidelines clean and inspect both beams Inspect the fillet welds on the bottom top and sides of the two centre reinforcement compression gussets Only cracks in or through the weld fillets may be repaired Any cracks that propagate into or through the beam flanges top or bottom or web plates are not to be repaired and the beam must be replaced See Fig 1 Grind out the crack areas remove as much of the old fillet weld as possible Do not cut into the flanges or web Re weld ground out fillet build fillet weld to Y4 minimum 5 16 maximum and weld part number 800599 over existing plate as shown in Fig 2 Prime and repaint reworked areas 5 9 Reinstall beams into the suspension See Section 4 11 of the 800 Seri
35. nch bolts If the bolts are corroded or damaged replace with NEW fasteners See Fig 11 Torque 1 2 NC fasteners to 65 ft Ibs Torque 5 8 NC fasteners to 135 ft lbs See Table 2 and Appendix D Service Bulletin No 26 STEP 5 Repeat Steps 1 through 3 to complete alignment STEP 6 Torque ALL fasteners to values shown on Table 2 IMPORTANT FAILURE TO CHECK TORQUE MAY LEAD TO FASTENER FAILURE AND CONSEQUENT LOSS OF VEHICLE CONTROL AND VOID WARRANTY 30 DOUBLE PINCH BOLT STYLE E a SS 1 2 X 1 75 GR 8 FLANGED HEX CAP BOLT 1 2 ER G FLANGED HEX STOVER LUCKNUT TORQUE TO 65 FT LBS Se AG SINGLE PINCH BOLT STYLE 9 8 X 3 9 GR B FLANGED HEX CAP BOLT 0 8 GR G FLANGED HEX STOVER LOCKNUT TORQUE TO 135 FT LBS FIGURE 11 31 6 0 TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE AND CORRECTION Loose Spigot Caps Fasteners Not Torqued Properly Re torque to 135 ft Ibs And re check at 1 600 km 1 000 miles If repeated loosening occurs replace fasteners amp spigot cap if required Torque to 135 ft Ibs And re check at 1 600 km 1 000 miles See Sections 4 6 amp 4 7 Prematurely Loose or Worn Bushings Chemical Attack Petroleum Products or Worn Bushings Used in Installation or Cleaning Remove all traces of petroleum products and re bush See Sections 4 2 amp 4 3 Hard Part Wear Re Bush using oversize bushings see Sections 4 2 amp
36. ng oversize replacement bushings for the 40 000 Ib and 46 000 to 58 000 Ib Suspensions Refer to Table 6 for when to use STEP 8 Liberally lubricate the inside diameter of the torque rod eye and the outside diameter of the replacement rubber bushing with a quality rubber lubricant such as Rimslip or equivalent IMPORTANT Never use any mineral based oils greases jellies or solvent soaps as a lubricant To do so will lead to the premature failure of the bushing Place the torque rod on a solid level floor with the open eye end up Place a rubber bushing onto the eye so as the outside tapered end of the bushing just enters the eye Try to make sure the bushing is as even as possible to the eye With a heavy soft faced mallet quickly strike the bushing to drive it down into the eye See Fig 3 THE RUBBER PROTRUDING FROM THE TORHUE RUD EYE SHOULD BE EQUAL UN BOTH SIDES ENSURE THAT BUSHING TS EQUALLY SPACED ALL ARROUND BEFLRE STRIKING FIGURE 3 NOTE Repeat the above procedure for the ond bushing Then flip the torque rod over 180 degrees Tap with a mallet to drive the bushings completely through the eyes until they are positioned evenly in the eyes See Fig 3 STEP 9 Liberally lubricate the torque rod rubber bushings and the relevant spigots with a quality rubber lubricant IMPORTANT Never use any mineral based oils greases jellies or solvent soaps as a lubricant to aid in the assembly of the rubber bush
37. no alignment systems are available Locate the grease fitting on the FRONT spring eye pin steering axle Attach a plumb bob to this fitting so the point is just above the floor Mark the floor right under the bob point Repeat this procedure for the other pin This now gives two fixed measuring points that are referenced off the vehicle frame See Fig 10 28 NOTE Make sure to wrap the plumb bob string in the same direction on both grease fittings ensuring that the plumb bob string hangs in an identical manner on both sides With a good quality tape measure the distance from the front axle floor fixed points to the front flange on the torque rod axle brackets See Fig 10 Repeat for other side Now do side to side axle TRAM Compare these dimensions For the axles to be in alignment ALL of the dimensions MUST be within 1 16 See Fig 10 AXLE ALIGNMENT NO ALIGNMENT SYSTEM EN 1 ye Se N awa BOS L 5 5 O 2 AV O AN mH A Movs a a jaa Q N En ge QX K gt ax 2 a E n we FEE AAA 5 V a 7 4 QU C Side TRAM measurement must equal D Side TRAM measurement to within 1 16 1 5mm A Side measurement must equal B Side measurement to within 1 16 1 5mm FOR COMPLETE AXLE ALIGNMENT FIGURE 10 29 5 2 AXLE ALIGNMENT ADJUSTMENTS Should the results of Step 3 or 4 from Section 5
38. nt and power tools must be used in and according to the manufacturer s safety and operating instructions General Instructions 3 1 3 2 3 3 3 4 3 5 MATERIAL CLEANING all material shall be free from loose scale slag oil rust and other foreign material JOINT PREPARATION joint surfaces shall be free from loose scale and rust Burned surfaces shall be smooth within 1 32 TACK WELD use appropriate size electrode and same type as specified below Employ corresponding weld data from chart below PREHEAT weld joint area as specified in 4 0 CLEAN all slag and spatter between passes Welding Process es 4 1 4 2 4 3 USE REVERSE POLARITY electrode positive WELDING SPEED shown is the ABSOLUTE MINIMUM DO NOT WELD SLOWER THICKNESS in between those specified on the chart use data from column of next smaller weld size 5 0 4 4 4 5 4 6 4 7 4 8 39 MANUAL SHIELDED ARC PROCESS Thickness 1 4 3 8 Type 7018 7018 Electrode Size 1 8 1 8 Amperage 130 130 Voltage 22 22 Weld Speed I P M 9 6 Preheat to room temperature 70 110 deg F Number of passes depends on type and size of joint METAL INERT GAS PROCESS Thickness 1 4 3 8 Type E70T1 E70T1 Electrode Size 1 16 5 64 Amperage 250 350 Voltage 28 26 Weld Speed I P M 20 19 Preheat to room temperature 70 100 deg F Number of passes depends on size of joint ELECTRODE WIRE use E70
39. ork covered in Section 4 1 through 4 13 TOOL LIST Open End Wrench 9 16 3 4 15 16 1 1 8 1 5 16 Box Wrench Offset Preferred 9 16 3 4 15 16 1 1 8 1 5 16 Standard Socket 1 2 Drive 9 16 3 4 15 16 1 1 8 1 5 16 Extra Deep Socket 1 2 Drive 15 16 Impact Socket 1 2 Drive 9 16 3 4 15 16 1 1 8 1 5 16 Extra Deep Impact Socket 1 2 Drive 15 16 Torque Wrench 1 2 Drive 25 250 Ft Lbs CALIBRATED GENERAL TOOLS Socket Drive Ratchet 1 2 Drive Heavy Mallet Rubber Copper or Hide 2 lbs Copper Hide Hammer Large 12 Long Min Square Blade Screwdriver Pinch or Wrecking Bar 3 4 size Tape Measure 16 ft Vernier Caliper 6 0 Reading 001 Impact Wrench 1 2 Drive Bottle Jack 5 ton Wheel Chocks Various Wooden Blocks LUBRICANTS Rubber Lubricant Rimslip or equivalent Important Do not use oil or grease 4 1 FASTENERS This guideline is to be used for the inspection or replacement of Chalmers supplied fasteners ONLY Not supplied by Chalmers are the fasteners attaching the triangular frames and upper frame brackets to the vehicle frame For inspection and specification on these please refer to the vehicle manufacturer The fastener systems used in a Chalmers suspension are the key to the care and safe operation of the suspension These systems comprise of an SAE GR 8 flanged head bolt and SA
40. r than the 062 1 5 mm allowable a Chalmers supplied wear plate MUST be installed Contact Chalmers for details 4 11 22 NOTICE Should excessive wear or cracks be found during vehicle operations it may be SLOWLY driven to the nearest repair shop Failure to repair or replace excessively worn or cracked walking beams will lead to failure of the beam ends and consequent loss of vehicle control BEAM WEAR MEASUREMENT BEAM END WEAR A THICKNESS NON WORN B THICKNESS END WEAR Beam Wear Maximum Limit A Thickness minus B Thickness 062 1 5mm Maximum FIGURE 8 WALKING BEAM REPAIR REPLACEMENT Repair of the walking beam entails the use of electric arc welding and MUST be performed by a qualified shop See Appendix C Eng Bulletin 8904 and Appendix D Eng Bulletin 8905 for repair installation instructions and guidelines Replacement of the walking beams may be done in any shop without the use of special tools using the following steps as a guide STEP 1 If possible power wash the walking beam As a minimum the beam should be brushed with a hard bristle brush to remove road dirt accumulation STEP 2 Chock the front tires to prevent the vehicle from moving Remove all drive axle brake or wind up loads by placing transmission in neutral and releasing the spring or driveline brakes 23 STEP 3 Lift the rear of the vehicle Support the frame on stands so all weight
41. rosion or distortion If any of these are present or the restrictor can is missing it should be replaced It is recommended that both restrictor cans be replaced to assure evenness of ride and handling NOTE Should a cracked or missing restrictor can be found during vehicle operation it may be driven SLOWLY to the nearest maintenance shop for replacement ALL CRACKED OR MISSING restrictor cans MUST be replaced Failure to do so may lead to loss of vehicle control and consequent personal injury RESTRICTOR CAN REPLACEMENT Replacement of Chalmers restrictor cans may be achieved easily and quickly in any shop without the use of special tools using the following steps as a guide STEP 1 If possible power wash the restrictor can spring area As a minimum brush the area with a hard bristle brush to remove road dirt accumulations STEP 2 Chock the front tires to prevent the vehicle from moving Lift the rear of the vehicle support the frame on stands so as all weight is just taken off the suspension 15 NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Remove the two 3 8 NC fasteners holding the lower spring plate to the beam Discard the fasteners NOTE On 54 0 spread suspensions it may be necessary to remove either the front or rear tires to allow spring assembly remo
42. t Install and tighten NEW NC fasteners and hardened washers STEP 5 Torque the NC fasteners to 170 ft lbs See Table 2 For replacement of shock absorbers 800781 or 800670 the following steps may be used as a guideline STEP 1 Chock the front tires and set the park brake to prevent the vehicle from moving STEP 2 Remove the top and bottom 7 8 NC locknuts from the shock absorber Pull the shock absorber from the top and bottom shock brackets Discard the locknuts and shock absorber STEP 3 Carefully clean and relubricate the top and bottom shock absorber bracket threads Referring to Fig 7 install the replacement shock absorber onto the top and bottom shock brackets Install and tighten NEW 7 8 NC locknuts and hardened washers STEP 4 Torque the 7 8 NC fasteners to 170 ft lbs See Table 2 IMPORTANT FAILURE TO CHECK TORQUE MAY LEAD TO FASTENER FAILURE WITH CONSEQUENT PREMATURE FAILURE OF THE SHOCK ABSORBERS 19 SHOCK ABSORBER BEAM INSTALLATION FOR SHOCK ABSORBER NO 665174 ITEM DESCRIPTION MTY I SHOCK ABSORBER 4 2 SHOCK BRACKET 4 3 HEX CAP BULT 4 4 HEX CAP BOLT 4 5 STOVER LOCKNUT 8 5 WASHER 8 SPACERS MAY BE REQUIRED DEPENDING LPEN FRAME OUTSIDE TO OUTSIDE DIMENSION Sy i OEE TORQUE TO 2 170 FT LES FIGURE 6 20 SHOCK ABSORBER AXLE INSTALLATION FOR SHOCK ABSORBER NO 800670 800781
43. to side centre and axle operating planning angle They are factory set and play NO part in the alignment process See Fig 4 The four 2 per axle bottom torque rods set the axle spread axle operating angle and axle alignment These rods are the ONLY means of making periodic adjustments for axle alignments See Fig 4 The Chalmers 800 Series Suspension allows for the precision alignment of each axle by the use of fine threads cut into the bottom torque rod tubes These rods incorporate left and right hand cut threads on the same tube thus by rotating the tube the rod length may be increased or decreased within the limit of the rod to achieve the desired alignment To accommodate all suspension capacities Chalmers uses two sizes of torque rods and tubes See Table 5 and Fig 11 TABLE 5 CAPACITY TORQUE ROD SIZE DIAMETER 36 000 Ibs to 1 2 3 8 Outside Dia 40 000 Ibs 46 000 lbs to 2 2 7 8 Outside Dia 58 000 Ibs 27 5 1 AXLE MEASUREMENT Measurement and alignment of a vehicle fitted with a Chalmers 800 Series Tandem Suspension may be done with any of the commercially available alignment systems If this type of specialized equipment is not available alignment may be carried out using a tape measure and plumb bob No matter which method is used due to the compressible design of the Chalmers rubber torque rod bushing ALL measurements and adjustments MUST be made with the bushings in a neutra
44. val STEP 4 Pull the lower spring plate spring and restrictor can as one assembly outward off the beam See Fig 5 VENT HULE Cif existing SHOULD BE FREE OF DIRT STEP 5 Separate the restrictor can spring and lower spring plate Discard the restrictor can Using a wire brush or scraper remove rust and road accumulations from the spring plate Clean out the centre vent holes in the beam and lower spring plate See Fig 5 Inspect the lower spring plate for visual cracks If cracked replace Contact Chalmers for details STEP 6 Turn the spring upside down so as the old top is now down Place on lower spring plate inserting the spring dowel into the centre spring hole Place the replacement restrictor can over the spring Make sure the can centre locator is in the centre spring hole See Fig 5 STEP 7 Lift and place as one assembly the lower spring plate spring and restrictor can onto the beam Line up the 3 8 fastener holes STEP 8 Install and tighten the new 3 8 NC spring plate fasteners Torque to 35 ft lbs See Table 2 STEP 9 Repeat Steps 3 through 8 to complete Before removing vehicle from stands check both restrictor cans for an even gap around the spring Adjust if required 16 4 6 SPIGOT CAP INSPECTION The spigot caps are part of the Chalmers torque rod joint system and play a key part in this system by placing a small amount of end compression to the rubber bushing and
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