800 SERIES HEAVY DUTY SERVICE MANUAL
Contents
1. 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 1 1 1 2 1 3 1 4 1 5 1 6 1 0 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 hanger 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 The 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 de2. 800 SERIES HEAVY DUTY SERVICE MANUAL 65 000 100 000 LB PART EDOC002 CHALMERS SUSPENSIONS INTERNATIONAL INC 6400 NORTHAM DRIVE MISSISSAUGA ONTARIO CANADA LAV 1 905 362 6400 VOICE 905 362 6401 FAX OUR EDGE IS OUR PRODUCT Contents 11 15 15 17 17 18 19 21 22 23 23 24 27 29 GENERAL INFORMATION INTRODUCTION TO THE SUSPENSION 2 1 SUSPENSION PART SERVICE INSPECTION REQUIREMENTS GUIDELINE TO THE INSPECTION AND REPLACEMENT OF SERVICE PARTS 4 1 ER EE 4 2 TORQUE ROD BUSHING INSPECTION 4 3 TORQUE ROD BUSHING REPLACEMENT 44 RESTRICTOR CAN INSPECTION 4 5 RESTRICTOR CAN REPLACEMENT 4 6 SPIGOT CAP INSPEC LION cidos 4 7 SPIGOT CAP REPLACEMENT 4 8 WALKING BEAM INSPECTION 4 9 WALKING BEAM REPAIR REPLACEMENT 4 10 SADDLE 4 11 RUBBER SPRING INSPECTION 4 12 RUBBER SPRING REPLACEMENT AXLE ALIGNMENT cece ce eee ee eee ee enone 5 1 AXLE MEASUREMENT 5 2 AXLE ALIGNMENT ADJUSTMENTS TROUBLE SHOOTING 1 0 2 0 3 0 4 0 5 0 6 0 1 APPENDIX A APPENDIX B APPENDIX C GENERAL INFORMATION This manual is to be used for the service of a Chalmers 800 Series Tandem Suspension 65 000 to 100 000 lbs capacity and is intended to give guidance and recommendation for the care maintenanc
3. Damaged Spring Replace spring See Sections 4 11 amp 4 12 Tire Pressure Check tire pressure and inflate to manufacturers specifications Damaged Spring Replace spring See Sections 4 11 amp 4 12 Insufficient Clearance Between Beam Stop and Beam Replace with correct length stop 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 Restrictor Can Replace both restrictor cans See Sections 4 4 amp 4 5 Damaged Spring Replace spring See Sections 4 11 amp 4 12 Insufficient Beam Stop Beam Clearance Replace with correct length stop PROBLEM Vehicle Does Not Sit Level Vehicle Unstable Rolls Vehicles Rides Excessively Hard Vehicle Handles Poorly WEAR LIMIT FOR OVERSIZE BUSHING 2 530 Max 800009 2 500 Min Bushing 2 530 Max 800009 2 500 Min Bushing 31 TABLE 6 SPIGOT WEAR LIMITS ITEM PART NO WEAR LIMIT FOR STANDARD BUSHING 1 800021 Spigot 2 2 530 800010 Min Bushing 4 02P00141 Spigot 2 2 530 800010 Heavy Duty Min Bushing SERVICE BUSHING WEAR MEASUREMENT To determine Wear take two measurements 90 de apart A A and B B as shown or measure 2 The smaller of the two dimensions is to be taken as the wear limit See Table 6 for values NOTE If spigot is
4. HEX CAP BOLT FLG 21 HEX CAP BOLT 14 17 5 26 RESTRICTOR CAN FIGURE 1A 65 000 Ibs suspension shown 4 VER LOADGUARD SPRING 3 BEAM SPRING PLATE FRAME HANGER L H R H DESCRIPTION SUSPENSION NOMENCLATURE HI HI DAPTOR BASE AP BOLT 18 T ROD AXLE BRKT RHF LHR EX CAP BOLT I SPACER 2 REBOLND STOP 7 T ROD AXLE BRKT LHE RHR 0 0 HEX 2 2r H 2 28 HARDENED WASHER 24 HEX CAP BOLT 25 STOVER LOCKNUT 26 STOVER LOCKNU 27 STOVER LOCKNU FIGURE 1B 80 100 000 Ibs suspensions shown TORQUE ROD BUSHING SPIGOT CAP 2 JOINT Pg UPPER FRAME BRACKETS 6 UPPER TORQUE RD 7 LOWER T ROD ADJUSTABLE 425 H D RESTRICTOR CAN Po OADGUARD SPRING 3 BEAM SPRING PLATE BEAM FRAME HANGER L H R H ITEM 1 TID DESCRIP 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
5. use welding grade C02 cover gas Minimum Dew Point 50 or 95Ar 5C02 REGULAR SETTING 35 48 cu ft per hour 4 4 4 5 4 6 4 7 4 8 Welding Sequence PREHEAT to temperature as specified in Section 4 0 CHIP AND BRUSH all slag and spatter between passes grind out all defects 5 1 5 2 5 0 35 Inspection 6 1 Visually inspect every completed row Repair 7 1 Prior to any repair work read all safety notes in Section 2 0 7 2 Prior to any installation support the vehicle on stands apply brakes and block wheels 7 3 Prior to any welding read all general notes and welding process in Sections 3 0 4 0 5 0 and 6 0 7 4 Remove both beams from the suspension clean and inspect 7 5 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 7 6 Grind or air arc out the crack areas Do not cut into the flanges 7 7 Reweld beam end web and stop plates Build welds to minimum 5 16 maximum fillets 7 8 Prime and repaint reworked areas 7 9 Reinstall beams into suspensions Check all bolts for correct torque See Technical Service Bulletin 8018 7 10 Remove all stands and wheel blocks cracks cracks Repairable End Non Repairable End Figure 1 6 0 7 0 36 APPENDIX C REPLACEMENT amp WELD INSTRUCTIONS Saddle We
6. its design by providing oversize replacement bushings for the 65 000 Ibs to 100 000 Ibs Suspensions Refer to Table 6 for when to use 4 3 12 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 HIE 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 7 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 ass
7. 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 neutral 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 25 STEP 3 Using 8 relevant alignment system and following all the manufacturers operating and safety instructions take measurements of the axle alignment Compare these to the vehicle m
8. 0135 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 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 4 12 5 0 24 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 TABLE 5 CAPACITY TORQUE ROD SIZE DIAMETER 60 000 Ibs to 2 2 7 8 Outside Dia 80 000 lbs 100 000 lbs 2 2 7 8 Outside Dia 1000 000 lbs 2 3 Outside Dia Upper Torque Rods Lower Torque Rods 5 1 AXLE MEASUREMENT Measurement and alignment of a vehicle fitted with a Chalmers 800 Series Tandem Suspension may be done with any of
9. 65 000 lbs 800055 800010 800009 100 000 lbs 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 SPIGOT CAP REPLACEMENT Replacement of the 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 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 Fai
10. 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 Spigot Cap On the daily walk around visually inspect for missing cracked broken or loose caps Replace as required or retorque See Sections 4 6 amp 4 7 and Table 3 for guidelines 1000 Mile PART ACTION P D I 1600 KM DLY MTH YRLY Walking Inspect for wear and cracks See Beam Sections 4 8 amp 4 9 for guidelines Inspect for beam free float in axle saddles 1 75 45mm fore and aft 38 10mm side to side See Section 4 8 Saddle Inspect for wear See Sections 4 10 for guidelines Axle Bracket Visually inspect for road damage or Hanger cracks Replace any damaged parts Bracket Assy as required Contact Chalmers for guidelines Rubber Visually inspect for chemical Spring damage deep tears and deformed springs Replace as required See sections 4 11 amp 4 12 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 we
11. SLNIOd 8 Ba TY YOOTA VE 85 Vs ACIS 9 D ENN AXLE ALIGNMENT NO ALIGNMENT SYSTEM 26 27 5 2 AXLE ALIGNMENT ADJUSTMENTS Should the results of Step 3 or 4 from Section 5 1 show that the axles are not within either the vehicle manufacturers specifications or the Chalmers recommended guidelines an axle adjustment will be required This may be done without the use of any special tools using the following steps as a guide 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 10 NOTE Ifthe 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 visu
12. 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 5 8 fastener holes STEP 8 Install and tighten the new 5 8 NC spring plate fasteners Torque to 135 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 17 SPIGOT CAP INSPECTION The spigot caps are part of the Chalmers torque rod joint system and play 8 key part in this system by placing 8 small amount of end compression to the rubber bushing and providing end retention to the joint The suspension capacity and spigot cap used is shown in the following Table 3 4 6 TABLE 3 JOINT SIZE CAPACITY SPIGOT CAP NO BUSHING O E M SERVICE 2
13. Torqued Properly Replace torque rod and torque check pinch bolts See Table 2 Worn or Loose Upper Torque Rod Bushings Re Bush upper torque rods See Sections 4 2 amp 4 3 Wet Highly Abrasive Road Conditions Add wear pads to beam or replace beam See Sections 4 8 amp 4 9 Axles Out of Align Re Align See Sections 5 1 amp 5 2 Tire Pressure Check tire pressure and inflate to manufactures specification 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 No Shocks Fitted Install shock kit Tire Pressure Check tire pressure balance and inflate to manufacturers specifications PROBLEM Loose Spigot Caps Prematurely Loose or Worn Bushings Adjustable Torque Rod Tube Pull Out or Back Off Walking Beam Touching Hanger Bracket Assembly Premature Beam End Wear Excessive Tire Wear Excessive Axle Movement Excessive Wheel Bounce or Hop 20 POSSIBLE CAUSE AND CORRECTION Broken or Missing Restrictor Can Replace both restrictor cans See Sections 4 4 amp 4 5 Damaged Spring Replace spring See Sections 4 11 amp 4 12 Damaged Walking Beam Replace walking beam See Sections 4 9 In a New Vehicle High Low Beam Installation Problem Replace incorrect beam Broken or Missing Restrictor Can Replace both restrictor cans See Sections 4 4 amp 4 5
14. ally 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 pinch bolts If the bolts are corroded or damaged replace with NEW fasteners See Fig 10 Torque 5 8 NC fasteners to 135 ft lbs See Table 2 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 28 SINGLE PINH BOLT STYLE 9 8 X 3 5 RR FLANGED HEX CAP BOLT 3 8 GR G FLANGED HEX STOVER LOCKNUT TORQUE TO 135 FT LBS FIGURE 10 29 6 0 TROUBLE SHOOTING POSSIBLE CAUSE AND CORRECTION Fasteners Not Torqued Properly Re torque to 135 ft lbs 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 lbs And re check at 1 600 km 1 000 miles See Sections 4 6 amp 4 7 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 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 Eye Pinch Bolts Not
15. anufacturers specification If none are available the following may be used as 8 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 no alignment systems are available Locate the grease fitting on the FRONT spring eye pin steering axle Attach 8 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 9 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 9 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 9 FIGURE 9 e 0911 0 Juouromseaw ANVUL IPIS C ien juauramseau NVUL OPIS O De I 91 1 UTM 0 SPIS 0 enbo asnu JUOUWIDINSBOWI APIS V LNANNDOTTV 4 IX V ALA TdINOO YOA
16. ar Pads 1 0 Scope 1 1 This procedure shall be used when replacing and welding Chalmers Suspensions International Inc saddle wear pads 2 0 Safety 2 1 The following safety instructions must be read and followed Failure to do so could lead to serious injury or possible loss of life 2 2 Prior to any work commencing on the vehicle the cargo compartments and delivery systems must contain a non explosive and non toxic atmosphere 2 3 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 2 4 All welding equipment and power tools must be used in and according to the manufacturer s safety and operating instructions 3 0 General Instructions 3 1 MATERIAL CLEANING all material shall be free from loose scale slag oil rust and other foreign material 3 2 JOINT PREPARATION joint surfaces shall be free from loose scale and rust Burned surfaces shall be smooth within 1 32 3 3 TACK WELD use appropriate size electrode and same type as specified below Employ corresponding weld data from chart below 3 4 PREHEAT weld joint area as specified in 4 0 3 5 CLEAN all slag and spatter between passes 4 0 Welding Process es 4 1 USE REVERSE POLARITY electrode positive 4 2 WELDING SPEED shown is the ABSOLUTE MINIMUM DO NOT WELD SLOWER 4 3 THICKNESS in between those specified on the chart use d
17. ar in normal service The wear rate is dependent on 8 number of factors such 8 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 GUIDELINES TO THE INSPECTION AND REPLACEMENT OF SERVICE PARTS Recommended tools needed to carry out the work covered in Section 4 1 through 4 13 TOOL LIST Open End Wrench 9 16 3 4 15 16 1 1 8 1 5 16 Box Wrench Offset Preferred 9 16 3 4 15 16 1 1 8 1 5 16 Standard Socket 1 2 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 Ibs 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 0 4 1 FASTENERS This guideline is to b
18. ary 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 7 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 1 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 21 BEAM INSTALLATION SADDLE INSPECTION The Chalmers 800 Series Saddles have been designed with three wear pads intended to prolong the life of the Chalmers Walking Beam See Fig 8 These pads located below the beam and to each side are designed to wear down over time and be replaced The rate of wear on these pads will vary depending on the operating conditions axle loading and distance travelled Chalmers recommends inspecting the saddles for pad wear at the i
19. ata from column of next smaller weld size 37 4 4 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 4 5 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 4 6 ELECTRODE WIRE use E70T1 electrode wire or equivalent 4 7 COVER GAS use welding grade C02 cover gas Minimum Dew Point 50 or 95Ar 5C02 4 8 REGULAR SETTING 35 48 cu ft per hour 5 0 Welding Sequence 5 1 PREHEAT to temperature as specified in Section 4 0 5 2 CHIP AND BRUSH all slag and spatter between passes grind out all defects 38 Inspection 6 1 Visually inspect every completed row Repair 7 1 Prior to any repair work read all safety notes in Section 2 0 7 2 Prior to any installation support the vehicle on stands apply brakes and block wheels 7 3 Prior to any welding read all general notes and welding process in Sections 3 0 4 0 5 0 and 6 0 7 4 Remove beam s from the suspension clean and inspect 7 5 Clean saddle s prior to beginning any work 7 6 Grind or air arc out the welds securing the wear pad plates to
20. below min dimension shown in Oversize Table contact Chalmers for N ND 2 Joint 800 Series Tandem Truck 60 000 to 100 000 Ibs Capacity guidelines Comments Tandem Axle Tandem Axle Restrictor Can Available and Application Chart T 32 APPENDIX A 65 000 lbs to 80 000 lbs Style Standard Optional Std Std 100 000 lbs Style Usage by Model Capacity 800 XX Series 65 80 000 lbs 800 XX Series 100 000 lbs C 0 188 0 38 TRUCK SUSPENSION MODEL B 14 19 12 00 A 4 44 4 62 Part No 373032 07S00001 Restrictor Can 26 26 HD 33 APPENDIX B 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 equipment and power tools must be used in and according to the manufacturer s safety and o
21. e 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 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 SAFETY 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
22. e 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 SAE 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 3 4 Dia 65 000 Tower to Tower Adapter Assembly to 80 000 5 8 Dia 65 000 ALL Torque Rod Joints amp to Torque Rod Eye Pinch Bolts 100 000 Spring Plate to Beams 3 8 Dia 65 000 Rebound Stop to Hanger Bracket to Assembly 100 000 Single 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 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 4 250 280 Value for tower to tower adapter assembly For all other uses contact Cha
23. embly of the rubber bushed 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 3 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 14 TORQUE ROD INSTALLATION UPPER TORQUE 005 4 p L N lt pa we 2 4 SE DB DNG 65 000 LBS S CAPACITY SUSPENSION UPPER TORQUE RODS 805131 80 000 to 100 000 LBS CAPACITY Zeie SUSPENSION FIGURE 4 15 RESTRICTOR CAN INSPECTION The Chalmers spring system comprises 01 8 rubber spring a
24. ing 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 6 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 B 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 4 9 20 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 Remove the spring plate spring and restrictor can following Steps 3 and 4 in Section 4 5 STEP 5 Remove the upper and if necess
25. ld 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 4 2 10 SPIGOT JOINTS 800021 Spigot Base 2 Joint 800055 Spigot Cap 2 Joint 800010 T Rod Bushing 2 Joint 800009 T Rod Bushing Oversize 2 Joint 02P00141 Spigot Base H D 2 Joint Service Bushing NUMBER 2 JOINT ASSEMBLY STANDARD BASE 2 Joint 800021 Base 800 Series Tandem Truck 65 000 lbs Capacity all Rods amp 80 100 000 lbs Capacity upper Rods 2 Joint 02P00141 Base 800 Series Tandem Truck 80 100 000 Ibs Capacity lower Rods NUMBER 2 JOINT ASSEMBLY HEAVY DUTY BASE FIGURE 2 11 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 device
26. lmers 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 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 The Chalmers bushings 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 shou
27. lure to check torque may lead to fastener failure and consequent loss of vehicle control and void warranty 4 7 8 WALKING BEAM INSPECTION The Chalmers 800 Series Walking Beam is 8 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 75 45mm fore and aft and 38 10 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 walking beam replacement See Fig I Appendix C 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 6 and may lead to unnecessary beam repair replacement Inspection of
28. nd 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 A 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 corrosion or distortion If any of these are present or the restrictor can is missing it should be replaced It is recommended tha
29. ntervals shown in Section 3 0 Service Inspection Requirements and any time the beam is removed from the suspension Inspect the pads on all four saddles looking for wear Pads which have wear that exceeds of the pad material thickness should be replaced Instructions for the replacement and welding of new pads are found in Appendix C Side Wear Pads Cam Wear Pad EN FIGURE 8 4 10 22 RUBBER SPRING INSPECTION The Chalmers patented rubber springs used in the 800 Series Suspensions are manufactured to very exacting standards from 8 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 4 11 TABLE 4 CAPACTY SPRING SIZE PART NUMBER 36 000 lbs 15 15015 40 000 Ibs to 58 000 lbs 20 15002 65 000 Ibs to 100 000 Ibs 26 15026 Under normal operation the Chalmers rubber springs do not require periodic maintenance or replacement Minor scrubbing from the restrictor can 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
30. perating instructions Scope 1 1 Safety 2 1 2 2 233 2 4 General Instructions 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 3 1 3 2 3 3 3 4 3 5 Welding Process es 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 4 1 4 2 4 3 1 0 2 0 3 0 4 0 34 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 E70T1 electrode wire or equivalent COVER GAS
31. rd 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 5 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 STEP 4 Separate the restrictor can spring and lower spring plate Discard the rubber spring Using 8 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 5 8 fastener holes STEP 7 Install and tighten the new 5 8 NC spring plate fasteners Torque
32. 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 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 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 23 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 s 8 minimum brush the area with a ha
33. s 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 torque 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 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 For wear limits refer to Table 6 Chalmers allows for wear in
34. sign 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 available in 60 and 65 axle spacing for the 65 000 lbs capacity and in 65 axle spacing for the 80 100 000 Ibs capacity The axle spacing and capacity is included as part of the suspension name e g Chalmers 860 65 Suspension or Chalmers 865 100 Suspension 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 1A shows an exploded view of a typical 800 Series Suspension 65 000lbs capacity Fig 1B shows an exploded view of a typical 800 Series Suspension 80 100 000 lbs capacity Throughout this manual parts will be referred to by the names shown on this figure 2 0 2 1 25 STOVER LOCKNUT 26 HARDENED WASHER 24 STOVER LOCKNUT 60 22 HEX CAP BOLT 23 STOVER LOCKNUT SUSPENSION NOMENCLATURE OG AXLE BRKT RHF LHR H FLGD 16 T ROD AXLE BRKT LHF RHR OVER ADAPTOR 15 SADDLE AN 11 SPACER 12 REBOUND STOP 18 HEX CAP BOLT 19 HEX CAP BOLT FLG 20
35. t 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 4 4 4 5 16 NOTE All stands and lifting devices MUST be of sufficient strength and rigidity to safely support the vehicle DO NOT WORK AROUND OR UNDER THE VEHICLE WHEN SUPPORTED ON LIFTING DEVICES STEP 3 Remove the four or three 5 8 NC fasteners holding the lower spring plate to the beam Discard the fasteners STEP 4 Pull the lower spring plate spring and restrictor can as one assembly outward off the beam See Fig 5 Standard 3 Point Spring Spring Plate Plate S Mounting Mounting 5 e FIGURE 5 STEP 5
36. 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 6 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 greater than the 062 1 5 mm allowable a Chalmers supplied wear plate MUST be installed Contact Chalmers for details 4 8 19 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 walk
37. the saddle Take special care not to damage the actual saddle assembly 7 7 Grind and prep the wear pad locations prior to install the replacement pads Again take care not to cut into the saddle assembly 7 8 Install the new plates welding should only occur at the ends of the plates so they may be easily removed should they require replacement See Fig 1 7 9 Prime and repaint reworked areas 7 10 Reinstall beams into suspensions Check all bolts for correct torque See Technical Service Bulletin 8018 7 11 Remove all stands and wheel blocks 6 0 7 0 39 Saddle Old Wear Pads Removed A Side Wear Pad Ka pm Cam Wear Pad Side Wear Pad 3 16 Fillet Weld on ends of Side Wear Pads only 3 8 Fillet Weld on ends of Cam Wear Pad only Figure 1
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