TMC 11T Air Suspension Service Manual
Contents
1. and deterioration replace or repair as necessary Carry out a visual inspection of the suspension for wear and damage repair or replace any worn or damaged parts as necessary e Check the axle alignment and readjust as necessary Axle alignment must be checked whenever severe kerb contact accidental damage occurs or the trailing leaf spring pivot bush is replaced Note These are the minimum recommended service requirements dependant on service conditions more frequent service and maintenance schedules may be required for the correct operation of the trailer axle As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 8 of 13 TR Service THE MULTIPLE CHOICE Replacement of Suspension Airbags The trailer can be driven at reduced speeds maximum of 40kph with no air in the airbags Blocking off of the air supply to a damaged punctured airbag is possible so that the remaining airbags can be used normally either by crimping the supply air line or blocking off the air port to the airbag to travel to a service area where the airbag replacement can be effected Note this is a temporary measure only and airbag replacement must be done effected as soon as practicable To replace an airbag the trailer should be parked preferably on a level hard surface with the brakes applied The trailer must be set at the correct ride height Suspension ai2. important to re check the positioning of all the suspension hangers and brackets to comply with the suspension s general arrangement drawing s dimensions for the suspension and that they are held to within the 2mm maximum variation before final welding of any of the suspension hangers All welding between the suspension hangers and the trailer frame is to be done using either low hydrogen electrodes or an approved equivalent MIG process Fully weld all around the top of each suspension hanger in a 6mm continuous fillet weld After installation of all the air suspension hangers it is recommended that all the hangers are fitted with either a channel angle or flat plate type of cross bracing between the suspension hanger and a chassis cross member Fully weld around the ends of the cross bracing onto the suspension hanger and onto the trailer s cross member The air bag pedestals should also be supported by either a full cross member brace or angled plate gussets back onto the trailer frame As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 3 of 13 TR Installation THE MULTIPLE CHOICE Trailer frame Cross member Cross member Trailer frame ras A AN 6 a r N N oe brace Pa x 4 l X j l i D NN Pivot bolt Pivot bolt hanger chins ell Pivot bolt ger Typical Suspension Hanger Brace Arrangement Ai
3. to the correct values as per the torque settings chart As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 9 of 13 TA Service THE MULTIPLE CHOICE Levelling Valve Adjustment The air suspension s levelling valve should be installed in the trailer frame in a protected position Care must be taken to ensure that the levelling valves linkage can move from the air suspension s maximum up position to the air suspension s maximum down position without any interference from any frame parts any suspension parts or any brake components The levelling valve linkage must be adjusted to keep the air suspension at its correct ride height Once the correct ride height for the air suspension is determined this height will be known from the air Suspension s model number or as marked on the air suspension s nameplate the ride height can be set The ride height is the dimension as shown on the diagram below e The trailer should be parked on level ground preferably with the trailer loaded or at least partly loaded and with the trailer brakes released e All air reservoirs should be fully charged before any suspension adjustments are performed After final adjustments have been made recheck all suspension ride heights with the air reservoirs all fully charged e To adjust the air suspension ride height loosen the clamps on the vertical linkage rod and Sl
4. TA THE MULTIPLE CHOICE TMC 11T Air Suspension Service Manual The Group TA THE MULTIPLE CHOICE 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 As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification TA Installation THE MULTIPLE CHOICE TMC 11T Air Suspension Installation Instructions The TMC 11T air suspension can be installed using normal workshop equipment no specialised tools Or equipment are required for the air Suspension s installation The air suspension is supplied normally as an assembly with the suspension hangers fitted to the trailin
5. fo tmcaus com au Wuhan TMC Axle Corporation Ltd TMC Transport Equipment Hubei Wuhan Economic amp Technological Asia Pte Ltd Development Zone No 21 Toh Guan Road East Wuhan Export Processing Zone A 1 Toh Guan Centre 05 28 Wuhan Hubei Singapore China 608609 Ph 86 027 8429 1843 Ph Fax 65 6316 2685 Fax 86 027 8429 1519 Email khdtan singnet com sq Email tmcwh china com The Group
6. g leaf springs the suspension pivot bushes installed the trailing leaf spring axle seats fully welded to the trailer axle and with the trailing leaf springs and U bolts installed onto the axle Although the U bolts will be tensioned during assembly it is recommended that they be re tensioned before final delivery as per the torque settings chart The order of assembly of the air suspension onto the trailer frame is not critical but positioning the various suspension hangers and other air suspension brackets correctly is very important A general arrangement layout drawing Is supplied with every air suspension kit additional copies are available on request from nearest TMC branches Recommended Installation Procedure Position two of the suspension hangers onto the trailer frame It is important to check with the air Suspension s general arrangement drawing for the suspension s correct dimensional layout to ensure that the trailer axle s required location in the trailer is correct Ensure that the hangers are fitted square to the frame and located in line longitudinally and transversely All dimensions longitudinal transverse and diagonal are to be within 2mm maximum variation Then position the other suspension hangers onto the trailer frame in the case of tandem and tri axle suspension installations ensuring that all the dimensions are held to within the 2mm maximum variation Tack weld all the suspension hangers and brackets in position It is
7. ide the rod through the clamp to achieve the correct suspension ride height Retighten the clamps The levelling valve linkage should be attached Clearance must be provided for the levelling to the cantre of the beam preferably to the valve linkage to move from maximum up to front of the axle tube 200 Approx maximum down suspension position in the trailer frame The linkage should be fitted as near to vertical as is possible As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 10 of 13 TA S ifications and Maintenance THE MULTIPLE CHOICE Recommended Torque Settings 1 Pivot bolt 1100 Nm M30 2 Axle U bolts 820 Nm M24 3 Top Shock Absorber bolt 300 Nm M24 4 Lower Shock Absorber bolt 300 Nm M24 5 Top Airbag stud nyloc nut 35 Nm M12 6 Bottom Airbag bolts 35 Nm M12 7 Front hanger wear plate bolts 70 Nm M12 4 Lower shocker bolt 5 Top airbag mount mts M12 3 Top shocker bolt M24 l Pivot bolt M30 7 Front hanger wear plate bolts M12 6 Bottom airbag mount bolts M12 As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 11 of 13 11T Series Air Suspension Part List TA THE MULTIPLE CHOICE Spare Part List ITEM k e m e k A e ai ooNon
8. licy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 5 of 13 TAC Installation MUETIPLE CHOICE Then align the remaining axles off the front trailer axle by rotating the alignment collars as described above on each axle until the axle centres on both sides of the trailer are equal It is also possible to do the axle alignment using a laser or optical aligning device designed for axle alignment if available After the axle alignment is completed tighten the front pivot bolt M30 and then tighten the front hanger wear plate retaining bolts M12 according to the torque settings chart Rotate alignment washer Use al9mm _ Square drive to rotate the alignment washer M30 suspension pivot bush e a a e e A CAUTION Loosen the M30 suspension pivot bush before attempting to align the suspension Retighten all bolts after alignment is completed As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 6 of 13 TR Installation THE MULTIPLE CHOICE Levelling Valve Installation The suspension s levelling valve should be installed in the trailer frame in a protected position Care must be taken to ensure that the levelling valves linkage can move from the air suspension s maximum up position to the air suspension maximum down position
9. n the rubber bellows and the airbag piston so that the airbag s base can be rotated to achieve alignment between the top and bottom airbag attachment bolt holes Once the two sets of bolt holes are correctly aligned retighten the lock nut in the airbag s piston The airbag can then be installed into the air Suspension Suspension catch straps must be installed generally as shown on the general arrangement drawing for the air suspension kit supplied the catch strap and mounting bolts are supplied with the suspension kit a suitable chassis bracket is to be installed in the trailer s frame to support the catch straps Care must be taken to position the top catch strap mounting bolt in the correct position and that the catch straps will not interfere with the operation of the air suspension or trailer axle in service Axle Alignment and Adjustment Procedure The alignment is measure from the centre of the kingpin to a centre point on each end of the front trailer axle Adjust the alignment as needed by rotating the collars on the front hanger on the air suspension s front pivot bolt to achieve the correct alignment The front pivot bolts must be loosened off so that the front pivot bolt can move backwards or forwards in the front suspension hanger when the alignment collars are rotated It is recommended that the alignment collars are rotated equally on each side of the suspension forwards or backwards to achieve the correct axle alignment As TMC s po
10. nrwvon OPAONOARWBNH ONMNNNNNNNNNEN ON OOOAON DOR WN O 31 0 wa 4 F E QTY PART NO MONONA NNNNNNAWAABRPNNAWAAWDANNNNNNNANDYD ARS 11 181811 ARS 11 181812 ARS 11 181813 ARS 11 18184 200971 606060 616161 ARS 11 282811 212170 211988 211989 ARS 11 181824 200973 211922 211933 211944 211955 200933 200922 200911 200974 ARS 11 181844 606061 606062 ARS 11 181826 OC LEDS YA DESCRIPTION 2 Leaf Spring LH 2 Leaf Spring RH Air Spring Spring Seat U Bolts Tracking Plate Spring Clamp Plate Shock Absorber Pivot Bolt Top Bolt Shocker Lower Bolt Shocker Pivot Bush Capscrew Self Locknut Self Locknut Self Locknut Self Locknut Washer H D Washer H D Single Coil Lockwasher Setscrew Plain Washer Air Chamber Bracket Serial Number Plate Reinforcement Plate Upper Shim Lower Shim Bolt Pivot Bracket 400mm Ride Height Pedestal Plate Cross Brace As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 12 of 13 TA THE MULTIPLE CHOICE TMC Axle Manufacturing Sdn Bhd No 79 amp 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 info tmc com my 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 _in
11. rbag shock absorber pedestal Trailer frame i Trailer frame AI N Ogy JI we 1 EHE E HE BaSS 67 FRAME AIRBAG Mounting of Airbag Pedestal to Frame Final Assembly The suspension s airbags are to be bolted onto the ends of the air suspension s trailing leaf springs and onto the air suspension s top airbag pedestals The airbag base plate has to be fitted first to the trailing leaf spring It is secured to the spring end first using the countersunk M 12x80 bolts and nyloc nuts the airbag is then bolted onto the end of the trailing spring using the MI 2x80 cap screws and MI 2x40 hex bolts The top of the airbag can then be attached to the top pedestal bracket using the M12 nyloc nuts Ensure all the bolts and fasteners are correctly tightened as per the recommended torque settings chart As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 4 of 13 TNG Installation THE MULTIPLE CHOICE M12x80 spring Assembly of Airbag to Air Suspension Spring If the orientation of the top and bottom bolts fasteners on the airbag does not align with the bolt holes in the trailing leaf spring and top airbag pedestal then the orientation can be changed by using the following procedure In the base of the airbag loosen the lock nut it may be necessary to break the seal betwee
12. rbags cannot be replaced with the air suspension deflated and sitting on its bump stops With the trailer at or near its correct ride height place either jacks or stands under the trailer s frame to support it Either block off the air supply to the airbag to be replaced or deflate the whole air suspension Remove the air supply line to the airbag and then the airbag can be unbolted from its position in the trailer s air suspension Replacement airbags as approved by the manufacturer must only be used Bolt the replacement airbag back into its correct position in the trailer and reconnect the air supply line to the airbag Torque all the mounting bolts to the correct values as shown on the torque settings chart Ensure when fitting the airbag that the rubber bellows are not twisted the top airbag plate and airbag base can be rotated if alignment is not correct Reconnect the air supply to the air suspension and remove the jacks stands from under the trailer frame check the air suspension for air leaks and correct as necessary Recheck the air Suspension s ride height and reset as necessary Shock absorber replacement The suspension s shock absorbers only need replacement when they become ineffective or leak oil The shock absorbers can be replaced by removing both the top and bottom mounting bolts and removing the shock absorber from the air suspension When replacing the shock absorber torque the top and bottom shock absorber mounting bolts
13. without any interference from other frame parts or other suspension and brake components The levelling valve should be mounted on an adequate chassis bracket and the linkage attached to a bracket mounted centrally on the trailer axles beam The levelling valve should be fitted to the centre axle on tri axle installations and to the rear axle on tandem axle installations The levelling valve linkage should be attached Clearance must be provided for the levelling to the cantre of the beam preferably to the valve linkage to move from maximum up to front of the axle tube 200 Approx maximum down suspension position in the trailer frame Suspension Ride Height The linkage should be fitted as near to vertical as is possible As TMC s policy is one of continuous development We therefore reserve the right to change or modify the specifications without prior notification Page 7 of 13 TA Service THE MULTIPLE CHOICE Recommended Service Schedule On Delivery or at 500 km e Check all torque settings for all fasteners Every 25 000km or Quarterly e Check all torque settings for all fasteners and inspect for visual damage and wear e Repair and replace parts as necessary Every 100 000 km or Annually Check all torque settings for all fasteners and inspect for visual damage and wear Check all suspension bushings for wear and deterioration replace or repair as necessary Check all leaf springs and U bolts for wear
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