TMC Axle Installation and Service Manual Manual - TMC Axle.pdf · TMC Axle Installation and Service Manual ... procedure. 1. Install bearings and wheel or hub on axle. 2. Install

The

TMC Axle Installation and Service Manual

Axle Installation

Group

As TMC’s policy is one of continuous development. We therefore reserve the right to change or modify the specifications without prior notification.

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Disclaimer

The author and publisher have made their best efforts to prepare this manual, and the information contained in this manual is current at time of printing (as specific at the later section of this sheet). However, TMC’s policy is one of continuous development. We therefore reserve the right to change or modify the specifications without prior notification. No part of this manual may be stored in a retrieval system, transmitted, or reproduces in any way, including but not limited to photocopy, photograph, magnetic or other record, without the prior agreement and written permission of the author and its respective company. TMC and the TMC logo are trademarks of TMC Axle Manufacturing Sdn. Bhd. in Malaysia and also TMC branches at other countries.

Versioning

Version Number: v 1.0.0 Version Date: November 04

Axle Installation


Page 3 of 31

Alignment It is the responsibility of the axle installer to properly align the axle. Alignment must meet the requirements regarding squareness to the vehicle center line, axle-to-axle dimensioning and parallelism between axles. Always follow industry standard alignment practices published by TMC (RP 708)

Axle Installation


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General Welding Recommendations In order to prevent possible twisting and distortion of the axle beam due to excessive welding, it is recommended that the axle be secured in an assembly fixture. There are several steps that can be taken to eliminate axle failures due to improper welding of axle components:

WARNING

Welding on the top and/or bottom of the trailer axle beam can result in stress risers (cracks) and premature failure of the axle beam.

• Welds may be horizontal or vertical of center line at both the front and rear of the axle, but under no condition are welds to be made in the “no weld” area marked in the adjacent illustration. The heat of welding and subsequent cooling causes the metal adjacent to the welding to become brittle. If this condition occurs in the high stress areas at the top and bottom of the axle, premature cracking may occur. Mounting can also be achieved by directly welding upper and lower brackets, etc., to the axle.

• The axle and all components being welded should be at a temperature of at least 60°F (15°C).

• All components welded to the axle should have close fitting surface-to-surface contact to avoid excessive welding of gaps on the axle.

• Clean the area to be welded to remove any dirt, grease or other material that may affect weld quality.

• Use a welding rod which meets American Welding Society Standards #E8018C-2 with a 3/16" maximum diameter.

• Do not break arc at ends of fillet, but back electrode up to fill.

Axle Installation


Page 5 of 31

CAUTION

Do not attach the welder ground cable to the axle so that a bearing is between area and ground point. Electric arcing can damage a bearing that is between the weld and the ground.

• Attach the welder ground cable to a component mounted on the axle such as the brake spider, air chamber brackets or camshaft support brackets. The ground cable attachment should be tight and clean.

• Set amperage and voltage per recommendation by electrode manufacturer. • Do not test arc on axle or brackets as this can result in notches or stress risers.

Spring Chair Mounting Extreme care must be taken while locating the spring chairs on a TMC axle to avoid problems like toe-in, toe-out and build-up of torsional stresses in the springs and suspension. Follow these guidelines to ensure proper installation of the spring chairs.

• Load bearing surfaces must be parallel to each other within 3/46" in 5".

NOTE: Please follow installation requirements of the suspension from manufacturer for parallelism.

• Preheat the spring chairs prior to welding in order to minimize local hardening. Weld to axle using 3/16" rod. Spring chairs (bottom plates) may also be mounted on underside of axle.

Hub, Bearings and Seal


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Hub, Bearings and Seal Removal

Always wear eye protection when working on an axle.

WARNING

1. Release the breaks. 2. Using a suitable socket (Part No. EUE-

1597A), remove the hubcap. NOTE: The socket used to remove the hubcap is also used to remove the single axle nut.



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• ve the adjustment nut, lock

. On axle with industry standard double lock

emove set screw from the spindle tab

• he outer jam nut and the spindle tab washer

6. the spindle. ndle.

3. On axle with a single axle nut: • Remove the cotter pin from the axle

nut. • Remove the axle nut and washer from

the spindle. 4. On axle with the double lock nut:

• Remove the outer axle nut and spacer tab washer.

• Bend the lock washer tab securing the adjustment nut back away from the nut. Remowasher and slotted washer from the spindle.

5

nut: • R

washer. Remove t

• Remove adjustment nut. Remove the hub washer from

7. Remove the outer hub bearing from the spi



Page 8 of 31

WARNING

Do not hit steel parts with a steel hammer. Parts can break, and flying fragments can cause injury. 8. Remove the hub from the spindle. It may

be necessary to tap the hub with a soft mallet to release the hub seal from the spindle.

9. Remove the inner hub bearing from the spindle or the inside of the hub.

CAUTION

Do not use a chisel to cut the seal. The shoulder can be damaged, resulting in a leak. 10. Remove the wheel seal from the spindle by gently tapping with a soft mallet. You can also use an

appropriate pry bar to pry the seal off the spindle, being not to gouge the shoulder. NOTE: The seal may have come off the spindle when the hub was removed.

Bearing Inspection

CAUTION

Please thoroughly clean bearing surfaces and cones. Do not mix a synthetic base grease or oil with an organic/mineral base lubricant. Do not spin fry bearing cones with compressed air. Bearing damage may result. After removing the axle hub, clean excess grease from the bearing cones. Inspect bearing cones for damaged rollers. Inspect bearing cups for damage to raceway. If any damage is found, replace the affected cone and cup as a set.



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Wheel Seal Installation The following instructions apply to installing wheel seals (Part No. TMC 2004-800723) in new TMC axle beam assemblies and servicing TMC complete axle assemblies.

CAUTION

To avoid damaging the wheel seal, support the hub and drum until the outer bearing cone and adjusting nut are installed. 1. If installing the seal on a new TMC axle beam assembly, remove the protective coating from the

bearing spindle threads, wheel seal surfaces and cotter pin holes. If installing the seal in an in-service axle, go to Step 2.

2. Remove all dirt, chips and hanging burrs from wheel or hubcap, making sure they are clean and dry.

CAUTION

Never install the seal in the hub and then force it into the axle spindle by tightening the axle nut. 3. Using seal installation tool (552-5239), place seal on spindle with printing "FLUID SIDE" facing

the end of the spindle. Tap lightly to seat seal. 4. Rotate the seal installation tool in V4-turn intervals until the seal is properly seated with the metal

face of the seal flush with the inner shoulder of the axle spindle. 5. Check for burrs or chips after installation.

Bearing Installation

CAUTION

Wheel seals should be installed before performing the wheel bearing adjustment procedure. 1. Coat inner bearing with lubricant recommended for your application. Install inner bearing. 2. Install wheel, taking care not to unseat or bend the oil seal. 3. Coat outer bearing with lubricant recommended for your application. Install outer bearing. 4. Slip on axle washer.


Am

Bearing Adjustment (Castellated Single Nut - Parallel Spindle)

CAUTION

Wheel seals should be installed before performing the wheel bearing adjustment procedure. 1. Install bearings and wheel or hub on axle. 2. Install bearing tab washer. 3. Install wheel bearing adjusting nut. Screw nut

against the bearing tab washer. 4. Make sure the brake shoes do not drag on the

brake drum. 5. Tighten the adjustment nut to 125 ft-lbs (169

Nm) while rotating the wheel. NOTE: Rotate the wheel in both directions to correctly position the bearings. 6. Back off the adjustment nut so that the cotter pin can be installed in the first hole. 7. Install cotter Din and lock in place.

Bearing Adjustment (TMC Double Lock Nut - Parallel Spindle)

Wp 123

45 N 6789

s TMC’s policy is one of continuous development. We therefore reserve the right to change or odify the specifications without prior notification.

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CAUTION

heel oil seals should be installed before performing the wheel bearing adjustment

rocedure.

. Install bearings and wheel or hub on axle.

. Install bearing tab/slotted washer.

. Install lock washer with keyway tab pointing outboard. (Make sure the two alignment tabs engage slots in the axle washer.)

. Install wheel bearing adjusting nut. Screw nut against lock washer.

. Tighten the adjustment nut to 125 ft-lbs (169 Nm) while rotating the wheel.

OTE: Rotate the wheel in both directions to correctly position the bearings.

. Back off the adjustment nut to the first available nut slot/lock washer tab combination.

. Bend one lock washer tab into the axle nut slot to prevent the nut from backing off.

. Install the spacer tab washer.

. Install the second axle nut and tighten to 250-300 ft-lbs (339-406 Nm)


Am

Filling Hub with Lube

D 1

2

3

NI Nt


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CAUTION

o not overfill the hub.

. Fill the hub with the specified lubricant (oil), through the hole in the hub cap, to the FILL mark. The installer should consult the hub manufacturer's specifications for lubricant capacity.

. Allow the oil to flow through the bearings and level off.

. Insert the rubber plug into the hole in the hub cap.

OTE: With axles equipped with a centralized tire inflation system, like Pressure Systems nternational, a vented hubcap must be used.

OTE: If using semi-fluid grease, TMC recommends using an electronic metering device o accurately reflect fill levels.

Brakes


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Brakes

Brake Components

Brake Shoe Removal 1. Manually release the brakes. 2. Remove the brake drum. 3. Remove the two brake retaining springs.

Heavy- duty brake spring pliers (Part No. E-2656) are available from TMC AXLE MANUFACTURING SDN BHD.

Brakes


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4. To remove the brake shoes: • Press down on the lower brake shoe to

disengage it from the anchor pin. • Move the lower shoe to the side of the

anchor bracket. • Lift the upper and lower shoes (still

connected by brake return spring) from the anchor plate.

5. Remove the anchor pins. If equipped with

a drive pin (P- Model brakes), remove this pin first. A brake shoe anchor pin press (Part No. E-2654) is also available from our TMC MANUFACTURING SDN BHD.

6. Remove the anchor pin bushing, if necessary.

7. Insert a screwdriver into the brake shoe and press the retaining tab of the cam roller clip while gently pulling the roller.

8. While maintaining pressure on the roller, turn the brake shoe over and Insert a screwdriver into the brake shoe and press the retaining tab of the opposite cam roller clip while gently pulling the roller.

9. Remove the roller and dip from the brake shoe. 10. Remove the roller from the dip and inspect for damage. NOTE: Inspect brake shoes and drum for wear. Follow brake manufacturer guidelines for minimum brake shoe thickness and maximum brake drum Inner diameter. A general guideline for replacing brake shoes is when the lining thickness is 1/4 Inch or less, or when the lining rivets have begun to contact the drum.

Brakes


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Brake Shoe Installation 1. Install the cam roller into the roller dip. 2. Install the roller and clip into the brake shoe. 3. Install the anchor pin bushings (if removed) in the spider. A brake shoe anchor pin press (Part No.

E-2654) is available from TMC AXLE MANUFACTURING SDN BHD. 4. Coat anchor pins completely with grease (STK0139220Lubriplate #630AA) and install anchor pins. 5. Connect the brake return spring to the

brake shoes. 6. Position the roller of the upper spring to

the brake shoes. 7. Position the lower brake shoe in the cam

head, and then place the other end of the hoe against the anchor pin.

8. Install the two brake retaining springs. Heavy- duty brake spring pliers (Part No. E-2656) are available from TMC AXLE MANUFACTURING SDN BHD.

9. Make sure the brake linings are clean. 10. Install the brake drum. 11. Adjust the brakes as described in this

manual. 12. Lubricate the camshaft bearings with the

specified grease.

Brakes


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Slack Adjuster Removal 1. Remove the cotter pin that secures the

slack adjuster/brake chamber clevis pin. Remove the clevis pin.

2. Remove the snap ring and washer that

secure the slack adjuster to the camshaft. Remove the slack adjuster.

Brakes

Am

Slack Adjuster Installation Haldex Automatic Slack Adjuster 1. Apply an even coat of anti- seize compound

(STK.70033) to serrated or splined surface of camshaft.

2. Install adjuster onto camshaft with adjusting nut away from brake chamber bracket.

3. Once adjuster is secured on camshaft and brake chambers have been installed, rotate adjusting nut clockwise until clevis holes line up with hole in adjuster arm. Distance from brake chamber bracket o clevis hole is approximately 7.62 inches for 16Vi Inch brakes and 8.25 inches for 12V4 inch brakes.

NOTE: There must be full thread contact between the clevis and push rod. The push rod must not extend more than 0.12 inch past the clevis and the threaded hole. Cut down the push rod if required.

Da 1

23

4

56


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CAUTION

o not push level into clevis to align pinholes. Use a 12-mm box wrench and rotate djusting nut clockwise to move slack adjuster into clevis.

. Rotate control arm away from adjusting hex nut and toward brake chamber until a definite Internal stop occurs. The "Installation Indicator" must fall within the slotted area with the brake released.

. Place anchor stud through the slotted S-cam bracket and install the lock nut.

. Insert anchor stud into control arm bushing. Tighten lick nut to 40-50 ft-lbs. (54-68 Nm). While tightening make sure that the control arm does not move out of position and the "Installation Indicator" remains within the slotted area.

. Check the installation by removing clevis pin and pressing stack adjuster into clevis. When the adjuster is released, the adjuster hole and clevis should remain in alignment.

. Install the clevis pin retainer and check that the clevis jam nut is tightly locked.

. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should be approximately 1.5 Inches. If the stroke is more than 1.5 Inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut clockwise.

Brakes


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Gunite Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound


2. Remove standard clevis and clevis pin from brake chambers and back off jam nut.

3. Secure the slack adjuster on the camshaft by assembling the spacing washers and snap ring.

4. Install chambers on brackets. 5. Remove special clevis from automatic slack

adjuster and install it on the air chamber push rod so that distance from the 0.50-inch clevis hole push rod to the chamber face is 7.62 inches. Tighten the jam nut.

NOTE: There must be full thread contact in the clevis boss. If the push rod threads protrude through the yoke more than 0.06 inch, remove the clevis and cut the push rod to length. 6. The slack adjuster should be in the correct location (7.62 inches from the center line of the clevis

pin hole in the slack adjuster to the air chamber mounting bracket face with the brakes in the OFF position). If it is not, reposition the slack adjuster by turning the adjusting nut manually until distance is 7.62 inches.

7. To align the automatic slack adjuster with the clevis: • Rotate the manual adjuster clockwise until the 0.50 hole in the slack arm is aligns with the

0.50 hole in the clevis. Install the clevis pin and cotter pins. • Align the 0.25 holes in the clevis and link. Install the 0.25 pin and cotter pin.

NOTE: Rotating the manual adjuster clockwise or counterclockwise will aid in aligning the 0.25 hole. 8. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should

be approximately 1.5 Inches. If the stroke is more than 1.5 inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut clockwise.

Brakes


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Bendix Automatic Slack Adjuster 1. Apply an even coat of anti-seize compound


2. Remove standard clevis and clevis pin from brake chambers and back off jam nut to approximately 1.25 Inches from end of push rod.

3. Remove the adapter from the slack adjuster and Install it on the push rod approximately 0.75 inches from the end of the rod. (For snap nut option: Install adapter 1.25 inches from end of rod. Install the retaining ring on the adapter bushing, making certain that it is in the bushing groove.)

4. Secure the slack adjuster on the camshaft by assembling the spacing washer and snap ring.

5. The slack adjuster should be in the correct location from the center line of the clevis pin hole in the slack adjuster to the air chamber mounting bracket face with the brake In the OFF position. If It Is not, reposition the slack adjuster by turning the adjusting nut manually until the correct location is achieved.

6. Install chamber on bracket with push rod in hole in yoke. 7. Turn the external adjusting nut in the direction indicated by the arrow on the crank arm until the

push rod enters the slack adjuster yoke assembly. (For snap nut option: Fully compress the legs of the retaining ring and continue turning the adjusting nut until the adapter is completely in the yoke. Check that the retaining ring is seated in both the yoke and adapter bushing groove by manually pulling on the slack arm in an attempt to separate the adapter bushing ands yoke.)

NOTE: The push rod must not extend 0.12 inch past the surface of the throat of the yoke. If required, cut down the push rod. 8. While holding the yoke in place, screw the adapter into the yoke and tighten the jam nut securely against the adapter. 9. The distance from the center line of the clevis pin to the chamber face should 7.62 inches. Turn the adjusting nut accordingly. NOTE: Torque required to rotate the adjusting nut in the direction opposite to the crank arrow must be as high as 70 ft-lbs. (95 N«m). 10. After installing the slack adjuster, apply service brakes with 120-125 psi. Push rod stroke should be approximately 1.5 inches. If the stroke is more than 1.5 inches, release the brake and manually readjust the slack adjuster by turning the adjusting nut.

Brakes

Am

2. and clevis pin from

3. 4-68

4. er on the camshaft

5. djuster should be in the correct

D

Meritor Automatic Slack Adjuster 1. Apply an even coat of anti- seize compound

(10 and 28 serration splines STK.70033, 37 serration splines - STK70255) to serrated or splined surface of camshaft. Remove standard clevis brake chambers and back off jam nut. Tighten the jam nut to 40- 50 ft-lbs. (5N»m). The push rod must now be amaximum of 0.17 inch less than flush with the collar or extending no more than 0.25 inch beyond the collar. Secure the slack adjustby assembling the spacing washers and snap ring. The slack alocation (7.67 inches from the center line of the clevis pin hole In the slack adjuster to the air chamber mounting bracket face with the brakes In the OFF position). If it is not, reposition the slack adjuster by turning the adjuster nut manually until the correct location is achieved.

cti Nw 6


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o not turn the manual djusting nut clockwise without first removing the pressure relief

OTE: If removed, tighten the pressure relief capscrew to 15-20 ft-lbs. (20-27 N*m)

. Final brake adjustment is recommended to ensure proper initial brake operation. The slack

CAUTION

aapscrew. Damage could occur to the pawl spring and adjusting pawl. When replacing he adjusting pawl and capscrew assembly, make sure the indicator is properly seated in ts bore.

hen reinstalling.

adjuster will then seek the proper working strike during vehicle operation.

Brakes


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Camshaft and Camshaft Bearing Removal

1. Remove the brake shoe and slack adjuster

as described in this manual. 2. Remove the snap rings from both ends of

the camshaft. 3. Remove the camshaft by sliding it out of

the axle housing and bearings. It may be necessary to tap the end of the shaft with a soft mallet to release it from the bearings.

Brakes


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4. Remove the two bolts and nuts securing the camshaft bracket to the axle housing.

5. Remove the remaining two bolts from the camshaft bracket and remove the bearing and seals from the bracket.

6. Inspect bearings and seals for wear and deterioration. Replace as necessary.

Brakes


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Camshaft and Camshaft Bearing Installation

Brake Camshaft Rotation: Cam brakes must be installed so the rotation of the camshaft is in the same direction as the brake drum when the vehicle is moving forward. 1. Clean the camshaft assembly. 2. Clean the faces of the anchor bracket and camshaft bracket. 3. Assemble camshaft bearing and seals into the camshaft bracket. Install the two bracket bolts and

nuts and tighten to 20-30 ft-lbs. (27-41 N«m). 4. Attach the camshaft bracket to the axle,

securing it with the remaining bolts and nuts. Tighten the bolts to 35-45 ft-lbs. (47-61 N»m).

5. Install the camshaft bearing assembly and O-rings into the spider.

6. Install the camshaft by sliding it into the bearing in the spider and the camshaft bracket.

7. Install the snap rings at both ends of the camshaft.

8. Install the slack adjuster and brake shoes as described in this manual.

9. Lubricate the camshaft bearings with the specified grease.

Brakes


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Brake Adjustment

1. Adjust the slack adjuster until the brake lining contacts the brake drum. 2. Apply the brakes using normal operating pressure (average line pressure should be 90 psi, but

not less than 80 psi). Check the following while brake pressure is applied. • Distance of push rod level. The maximum push rod travel should be no more than 2 inches as

regulated under FMVSS-121 and/or CMVSS-121. • Angle between push rod and slack adjuster. The angle, with brakes applied, should be 85° to

95°. • Brake lining to drum contact. A 0.010-inch feeler gauge should not fit between the lining and

the drum contact area. 3. Release the air pressure from the brake system and check to see that all brakes release to the

normal relaxed position. NOTE: When automatic slack adjusters are used, always follow the installation and adjustment procedures provided by the automatic slack adjuster manufacturer. Failure to follow he recommended procedure could result in improper operation of the automatic slack adjuster, resulting in reduced brake performance or premature lining wear.

Brakes


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ABS Sensor Replacement NOTE: ABS sensors must match the system. Do not mix sensors from different manufacturers. Removal 1. Manually release the brakes. 2. Remove the drum. 3. Disconnect the ABS sensor connector. 4. Remove the sensor from the sensor holder

by pulling straight out. 5. Remove the sensor retaining spring clip, if

necessary.

ABS Sensor Installation Note: be sure to use the correct spring clip for the sensor being installed. 1. Install the sensor retaining spring clip, if

removed. Into the sensor holder. 2. Install the ABS sensor into the spring dip

and sensor holder. Push the sensor in until it contacts the tooth wheel.

3. Connect the ABS sensor connector. 4. Install the brake drum (if using outboard

drum) 5. Adjust brakes as described in this manual.

Troubleshooting


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Troubleshooting

Troubleshooting Guide Problem Probable Cause Corrective Action

Brake shoes bound up at anchor pins Lubricate brake operating partsBrake hoses restricted Replace hosesBrakes out of adjustment Adjust brakesDamaged brake assembly Replace or repair as requiredSource of air supply shut off at tractor Open cutout cocks at rear of tractor

cab or push control valve "IN"Low brake line pressure Check air pressure gauge on tractor

- inoperative compressorBrake lines between tractor and trailer not properly coupled

Properly couple brake lines

Reservoir drain cook open Close drain cockLeaf spring broken Replace complete springBent axle Replace or straighten axleFrame or suspension out of alignment Straighten frame or align axlesOver or under inflation Inflate to proper pressureLoose wheel stud nuts or clamps Tighten wheel stud nuts or clampsLoose or tight wheel bearing adjustment Adjust bearingsAxle bent or out of alignment Straighten, align or replace axleTires not properly matched Match tiresImpproper acting brakes Correct brakes as requiredRapid stopping Apply brakes slowly when

approaching stopHigh-speed driving on turns Reduce speedOil, grease or foreign material on brake lining

Reline brakes

Brakes out of alignment Adjust brakesBrake drum out-of-round Replace brake drumDamaged brake chamber or internal assembly

Replace or repair as required

Leaky or broken hose between relay valve and brake chamber


Excessive heat cracks on drum

Rapid stopping or poor air flow to brakes Replace drum

Out of adjustment Adjust brakesBinding cam, anchor pins or chamber rod end pin

Lubricate and free up

Damaged brake assembly or brake drum out of round


ABS inoperableLack of lubrication Lubricate brake operating partsExcessive travel in brake chamber push rod

Adjust brakes

Restriction in hose or lines Repair or replaceDefective brake valve Replace brake valve

Grabbing brakes

Refer to ABS manufacturer's service literatureSlow brake application or release

Brake dragging

Brkes will not release

No brakes or insufficient brakes

Dog tracking

Uneven tire wear

Specifications and Maintenance


Page 26 of 31


Torque Chart

Component Torque ValueGrease 20-50 in-lbs (2-6 Nm)Hex Nut, 3/8-16, Grade 8 35-45 in-lbs (47-61 Nm)Hex Nut, 3/8-16, Grade 5 20-30 in-lbs (27-41 Nm)Adjustment Nut, Bearing 125 in-lbs (169 Nm)Axle Nut, Second 250-300 in-lbs (339-406 Nm)Outer Jam Nut 300-400 in-lbs (406 Nm)Air Chamber Nuts 80-100 in-lbs (108-136 Nm)Dust Shield Bolts 13-17 in-lbs (18-23 Nm)Hubcap 60-70 in-lbs (81-95 Nm)Hubcap Bolts 13-17 in-lbs (18-23 Nm)

Recommended Service and Maintenance Schedules

Component Surface to be Lubricated

Lubricant STK No.

Type of Lubrication

Frequency

Brakes Camshaft (four grease fittings per axle)

STK 013922

Lubriplate No. 630AA

Every 20,000 miles or 4 months

Brakes Brake Shoe Rollers Anchor Pins

STK 013922


100,000 miles or at brake reline

Brakes - Slack Adjuster

Slack Adjuster Grease Fitting

STK 013922


Every 20,000 miles or 4 months

Pro-Par Axle Bearings and Hubs STK 070045

All-Weather Oil SAE 80

100,000 miles or at brake reline

NOTE: Intervals are based on normal operations. Reduce Intervals to compensate for abnormal operations or severe conditions. During Inactive periods, sufficient lubrication must be performed for equipment preservation.



Page 27 of 31

Recommended Inspection Schedule NOTE: Intervals are based on normal operations. Reduce intervals to compensate for abnormal operations or severe conditions.

First Service • Check torque settings of all wheel nuts - On delivery

- After all wheel changes

After first 5000 km • Check and adjust all wheel bearings.

Every 5,000 km or Once a Month (Whichever Comes First) • Check ABS (if applicable) for proper operation. • Check secondary and parking brake system (if applicable) for proper operation. • Check tires and wheels (torque wheel nuts to proper torque). • Check axle fluid level, add fluid if required. • Check wheel seals for leaks. • Inflate tires to proper pressure. • Inspect brake system gladhands, hoses, tubing, chambers, valves and reservoirs for leaks or

damage. • Check chamber push rod travel and adjust brakes. • Check lining thickness (remove dust shields, if necessary). Do not remove wheels. • Visually check axle alignment.

Every 25,000 km or 4 Months (Whichever Comes First) • Inspect brake drums and wheels. • Inspect brake linkage and shoes. • Inspect brake lines and hoses for chafing, looseness and deterioration. • Test brakes for action, side pull and synchronization. • If equipped with ABS, run complete system check. • Perform soap suds leak test on entire air system. • Drain reservoirs. • Check axle alignment.

Every 100,000 km or 1 Year (Whichever comes first) • Remove the hubcaps and inspect the wheel bearings and lubricant. • Replace the lubricant if it appears badly contaminated. • Re-adjust the wheel bearings and re-torque the axle lock nut. • Replace the hubcaps and ensure the correct amount of lubricant is in the hub end. • Check that the hubcap gasket is not damaged. Replace as necessary. • Check the axle for brake wear; check the rest of the axle components for wear or damage. • Repair, adjust or replace as necessary.

Every 300,000 km or 3 Years (Whichever come first) • Remove was and inspect the wheel bearings, replace as necessary. • When re-assembling the wheel bearings, ensure they are correctly lubricated and adjusted.



Page 28 of 31

Important Torque Settings

Wheel Nuts Nm ft lbs ISO M22 550-600 400-450 BSF 7/8” 475-540 350-400 DIN M22 515-540 380-400 The wheel nuts must be re-torqued every month or after every wheel change. Nm ft lbs U-Bolts 500-540 370-400 Torque Arm Bolt 290-350 215-260 Pinch Bolt 95 70 Equalizer Bolt 290-350 215-260

Axle Part List


Page 29 of 31

Axle Part List

Spare Part List

ITEM QTY PART NO DESCRIPTION1 2 804345 Threaded Hub Cap5 2 800110 Axle Spindle Adjusting Nut6 2 800111 Axle Spindle Lock Washer9 2 800064 Outer Bearing Cone10 2 866250 10 Stud Brake Drum, BSF, 16½" X 7"

2 801163 10 Stud Brake Drum, JIS, 16½" X 7"2 866879 8 Stud Brake Drum, JIS, 16½" X 7"

11L 1 800089 10 Stud Hub Assy, BSF, L.H.1 800101 10 Stud Hub Assy, JIS-M, L.H.1 800097 8 Stud Hub Assy, JIS-M, L.H.

11R 1 800090 10 Stud Hub Assy, BSF, R.H.1 800102 10 Stud Hub Assy, JIS-M, R.H.1 800098 8 Stud Hub Assy, JIS-M, R.H.

12 4 800017 Cam Roller13 4 800018 Cam Roller Retainer14 2 800016 Shoe Return Spring15 4 800002 Anchor Pin Bush16 4 800015 Brake Retainer Spring17 4 800167 Brake Shoe Lined18 4 800013 Spring Retainer Pin19 4 800014 Anchor Pin20 2 800003 Dust Shield

Axle Part List


Page 30 of 31

ITEM QTY PART NO DESCRIPTION21 12 800067 Self Tapping Screw22 12 800069 Lock Washer23 1 801820 Axle Beam Assy, 1820mm Square Track

1 802417 Axle Beam Assy, 1820mm Round Track24L 10 800021 Stud, BSF, L.H., included with item 11

8 800025 Stud, JIS-M, L.H., included with item 1124R 10 800022 Stud, BSF, R.H., included with item 11

8 800026 Stud, JIS-M, R.H., included with item 1125 2 800065 Inner Bearing Cap, included with item 1126 2 800065 Outer Bearing Cap, included with item 1127 2 800723 Seal Assy - Grease, included with item 1128 2 800052 Slack Adjuster, 6" X 37" Spline29 2 800001 Cam Support Bushing30 8 800068 Self Tapping Bolt31 2 800005 Cam Shaft Bushing32 4 800032 Cam Shaft Seal33 2 800033 Spacer Washer, 1½" Dia.34 4 800034 Snap Ring, 1½" Dia.

35L 1 09690L Cam Shaft, 37-Spline, L.H.35R 1 09690R Cam Shaft, 37-Spline, R.H.36 2 800064 Inner Bearing Cone37 2 800104 Spacer Washer, 1¼" Dia.38 2 800102 Snap Ring, 1¼" Dia.

39L 10 800051 Capnut-outer, BSF, L.H., Optional39R 10 800052 Capnut-outer, BSF, R.H., Optional40 10 800053 Centering Washer, BSF, Optional41 2 802400 Brake Chamber Type 24, Optional42 2 803000 Brake Chamber Type 30, Optional43 2 803030 Brake Chamber Type 30/30, Optional

Applicable Axle Model:

• PFRD-245-167-10B • PFRD-245-167-10J • PFRD-245-167-8J

TMC Axle Manufacturing Sdn. Bhd. No 79 & 81 Jalan 5/10B

Spring Crest Industrial Park 68100 Batu Caves

Kuala Lumpur Malaysia

Ph +6 03 6187 7788 Fax +6 03 6187 6722

Email [email protected]

TMC Australia Pty Ltd 78 Star Crescent,

P.O.Box 5028 Hallam Vic 3803

Australia Ph +61 3 8786 3688 Fax +61 3 8786 3699

Email: [email protected]

Wuhan TMC Axle Corporation Ltd. Hubei Wuhan Economic & Technological

Development Zone Wuhan Export Processing Zone A-1

Wuhan Hubei China

Ph +86 027 8429 1843 Fax +86 027 8429 1519

Email: [email protected]

TMC Transport Equipment Asia Pte. Ltd.

No. 21, Toh Guan Road East Toh Guan Centre #05-28

Singapore 608609

Ph/Fax +65 6316 2685 Email: [email protected]

The Group

Documents

TMC Axle Installation and Service Manual Manual - TMC Axle.pdf · TMC Axle Installation and Service Manual ... procedure. 1. Install bearings and wheel or hub on axle. 2. Install