Chalmers 800
Chalmers 800
Chalmers 800
INTERNATIONAL INC.
800 SERIES
SERVICE AND
MAINTENANCE
MANUAL
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CHALMERS SUSPENSIONS
INTERNATIONAL INC. Contents
Page No.
1.0 GENERAL INFORMATION 1
This manual is to be used for the service of a Chalmers 800 Series Tandem
Suspension and is intended to give guidance and recommendation for the care,
maintenance, inspection and safe operation of the above suspension. It is not a
replacement for existing or future specific Pre-Delivery Inspection (P.D.I.) &
Preventative Maintenance Programs.
Before proceeding with any work on or with the suspension, please read this manual
completely to familiarize yourself with the maintenance and operation of the
Chalmers Suspension.
TAKE SPECIAL NOTICE of procedures 1.1 through 1.6 that must be followed
without exception when working on any procedures described in this manual.
1.1 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
1.2 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.
1.6 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 shortened suspension life or failure of a
part with consequent loss of vehicle control.
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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 center
(front-to-rear) of the steel walking beam. A sawhorse bracket assembly is attached
to the frame and provides mounting points for the lower torque rods that tie the
axles to the frame. The upper torque rods are fastened to brackets that bolt to the
frame side rails and to tower assemblies that are welded to the top of the differential
housings. See Fig.1.
The 800 Series Rear Suspension allows a high degree of both parallel and diagonal
articulation, while maintaining wheel load equalization to within 3%.
The 800 Series is also available in three different axle spacings: 54-inch, 60-inch,
and 72-inch axle-to-axle;. The axle-to-axle spacing dimension is included as part of
the suspension name, e..g. “Chalmers 854 Suspension” or “Chalmers 860
Suspension.”
Shock absorbers are optional on all versions of the suspension, and available in two
styles - beam mounted and axle housing mounted.
The rear suspension may be precision-aligned by adjusting the length of the lower
torque rods. These rods have both left and right hand threads cut on the same tube
so rotating the tube changes the effective length of the tube.
Throughout this manual, parts will be referred to by the names shown on this figure.
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The Chalmers 800 Series Suspension was designed to require minimum general
maintenance. The recommendations shown in the following chart are precautionary
and are aimed at avoiding future problems.
NOTICE:
The above chart was developed from Chalmers experience on parts subject to wear in
normal service. The wear rate is dependent on a number of factors such as load carried,
speed traveled, road bed 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.
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Recommended tools needed to carry out the work covered in Section 4.1
through 4.13.
TOOL LIST
GENERAL TOOLS
Wheel Chocks
LUBRICANTS
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, SAE GR.G flanged
head “Stover” locknut, and a proprietary thread locking adhesive. 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
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.
3/8” 35
1/2” 65
5/8” 135
3/4” 170
All 800 Series Suspensions incorporate rubber bushed torque rod joints that isolate
the vehicle from axle braking and driving shocks. To accommodate the full range of
suspension capacities, Chalmers has two sizes of bushing. See Fig.2 for details.
Both bushings are similar and they both absorb axle shock by compression. This
compression may give a false impression of a worn bushing. To reduce the chances
of prematurely replacing a good bushing, the following steps should be used when
inspecting all Chalmers bushings:
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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 as
the rubber bushing may be seen.
STEP 2 - Chock the front tires to prevent the vehicle from moving. Remove all
drive axle brake or wind up loads by placing transmission in neutral, releasing
spring brakes, or driveline brake.
STEP 3 - USING HANDS ONLY attempt to move the torque rod ends, checking
for FREE play. If free play is felt, the bushing should be replaced. (If in doubt
contact Chalmers).
NOTE: DO NOT USE A PRY BAR OR LEVER to check for free play. To do
so may lead to premature bushing replacement.
Replacement of Chalmers Torque Rod Bushings may be achieved easily and quickly
in any shop without the use of a press or special tools, using the following steps as a
guide.
STEP 1- If possible power wash the torque rod ends, as a minimum, the ends should
be brushed with a hard bristle brush to remove road dirt accumulations..
STEP 2 - Chock the front tires to prevent the vehicle from moving. Remove all
drive axle brake or wind up loads by placing transmission in neutral and releasing
the spring or driveline brakes.
STEP 3 - Lift the rear of the vehicle. Support the frame on stands so all weight is
just taken off the suspension.
NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity
to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE
VEHICLE WHEN SUPPORTED ON LIFTING DEVICES.
STEP 4 - Work on only one 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: On the axle towers, pry off the metal plug cap to access the joint nuts.
Keep the plug cap.
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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 planing 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 accu-
mulations 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:
Should the spigot show visual cracks, contact Charmers for guidelines.
For wear limits, refer to Table 6 and Appendix “A” Service Bulletin Re: Part No.
260002. Charmers allows for wear in its design by providing oversize replacement
bushings for the 40,000 lb. and 46,000/50,000 lb. Suspensions. Refer to Table 6
for when to use.
STEP 8 - Liberally lubricate the inside diameter of the torque rod eye, and the
outside diameter of the replacement rubber bushing with a quality rubber lubricant
such as Rimslip or equivalent.
IMPORTANT: Never use any mineral based oils, greases, jellies or solvent soaps as
a lubricant. To do so will lead to the premature failure of the bushing.
Place the torque rod on a solid level floor with the open eye end up. Place a rubber
bushing onto the eye so as the outside tapered end of the bushing just enters the eye.
Try to make sure the bushing is as even as possible to the eye. With a heavy, soft
faced mallet, quickly strike the bushing to drive it down into the eye. See Fig.3
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NOTE: Repeat the above procedure for the 2nd bushing. Then, flip the torque rod
over 180 degrees. Tap with a mallet to drive the bushings completely through the
eyes until they are positioned evenly in the eyes. See Fig.3.
STEP 9 - Liberally lubricate the torque rod rubber bushings and the relevant
spigots with a quality rubber lubricant.
IMPORTANT: Never use any mineral based oils, greases, jellies or solvent soaps
as a lubricant to aid in the assembly of the rubber 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 torque 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.
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.
Repeat Steps 1 through 11 for each torque rod to complete the suspension
rebushing.
When finished rebushing, check to see if the torque rods have been replaced as per
Fig.4.
The 46,000 and 50,000 lbs. Suspension upper rods, must be oriented as shown in
Fig.4.
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The Chalmers spring system comprises of a rubber spring and an enclosing metal
restrictor can. The purpose of the restrictor can is to provide specific ride, road
handling characteristics and protection to the spring.
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 as 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
that both restrictor cans be replaced to assure evenness of ride and handling.
STEP 5 - Separate the restrictor can, spring and lower spring plate;. Discard the
restrictor can. Using a wire brush or scraper, remove rust and road accumulations
from the spring plate. Clean out the center 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 center spring hole. Place the
replacement restrictor can over the spring. Make sure the can center locator is in the
center 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 two 3/8” fastener holes.
STEP 8 - Install and tighten the new 3/8” NC spring plate fasteners. Torque to 35ft.
lbs. See Table 2.
The spigot caps are part of the Chalmers torque rod joint system and play a key part
in this system by placing a small amount of end compression to the rubber bushing
and providing end retension to the joint.
Two sizes of torque joints are used in the Chalmers 800 Series Suspension. The
suspension capacity and spigot caps used are shown in the following Table 3.
TABLE 3
BUSHING
JOINT SIZE CAPACITY SPIGOT CAP NO.
O.E.M. SERVICE
AFTER JAN/93 40,000 lbs. 800201 22128 22129
#1
#2 46,000 lbs. 800055 800010 800009
50,000 lbs.
BEFORE JAN/93 36,000 lbs. 260002 22129
#0 40,000 lbs. Spare Part Only
NOTE: Torque rod Joint #1 superseded Joint #0 on all 40,000 lbs. 800 Series
builds starting Jan/l993.
All 40,000 lbs. 800 Series suspensions build before this date have #0 Joints and
spigot cap #260002. (Check for Part No.).
Spigot caps 800201 and 260002 are not interchangeable. See Fig.2.
Visual inspection of the spigot caps should be done on a daily basis. See Section
3.0 Service Inspection Requirements.
IMPORTANT: If a loose spigot cap is found retorque the 5/8” NC fasteners to 135
ft. lbs. See Table 2. Should persistent loosening occur, replace the 5/8”NC fastener
as hard part wear is affecting the bolt seat. See Table 2, and Appendix “A” Service
Bulletin Re: Part No. 260002.
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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.
NOTE: On the axle tower, pry off the metal plug cap to access the joint nuts.
Reinstall the cap when spigot cap replacement is finished.
STEP 3 - Remove the 5/8” NC fasteners and pry off the spigot cap, discard both.
STEP 4 - Press the replacement spigot cap into the ends of the torque rod bushings.
STEP 5 - Install and tighten new 5/8” NC torque rod joint fasteners. Torque to 135
ft. lbs. See Table 2.
IMPORTANT: Failure to torque check, may lead to fastener failure and consequent
loss of vehicle control.
Shock absorbers are provided on the 800 Series Suspension as an option to provide
specific ride properties for difference road conditions. The 800 Series suspension
may be fitted with either beam-mounted or axle mounted shock absorbers. See
Fig.6. and Fig.7. The replacement procedure is essentially the same for both types
of shock absorbers.
NOTICE:
Should a leaking or damaged shock absorber be found during vehicle operation, the
shock absorber should be removed immediately. See Section 4.9 shock replacement
step 1 to 5, or the vehicle may be driven SLOWLY to the nearest maintenance shop
for either removal or replacement.
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4.9 SHOCK ABSORBER REPLACEMENT
Refer to Fig.6 or Fig.7 to determine which shock absorber option is fitted to your
vehicle.
For replacement of beam mounted shock absorber #665174, the following steps
may be used as a guideline:
STEP 1 - Chock the front tires and set the park brake to prevent the vehicle from
moving.
STEP 2 - Remove the top and bottom 3/4” NC fasteners from the shock absorbers.
Pull the shock absorber from the bottom beam shock bracket. Discard the fasteners
and shock absorber.
STEP 3 - Place the bottom eye of the replacement shock absorber into the beam
bracket. Refer to Fig.6. Install and tighten NEW 3/4” NC fasteners and hardened
washers.
STEP 4 - Adjust the shock absorber length so as the top eye lines up with the hole
in the upper shock bracket. Install and tighten NEW 3/4” NC fasteners and
hardened washers.
STEP 5 - Torque the 3/4” NC fasteners to 170 ft. lbs. See Table 2.
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For replacement of shock absorbers #800781 or 800670, the following steps may be
used as a guideline:
STEP 1 - Chock the front tires and set the park brake to prevent the vehicle from
moving.
STEP 2 - Remove the top and bottom 7/8” NC Locknuts from the shock absorber.
Pull the shock absorber from the top and bottom shock brackets. Discard the
locknuts and shock absorber.
STEP 3 - Carefully clean and relubricate the top and bottom shock absorber
bracket threads. Referring to Fig.7. Install the replacement shock absorber onto the
top and bottom shock brackets. Install and tighten NEW 7/8” NC locknuts and
hardened washers.
IMPORTANT:
FAILURE TO TORQUE CHECK MAY LEAD TO FASTENER FAILURE WITH
CONSEQUENT PREMATURE FAILURE OF THE SHOCK ABSORBERS.
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4.10 WALKING BEAM INSPECTION
The Chalmers 800 Series walking beam is a key part of the load support and
equalization system of the suspension. It not only acts as a lower support and
anchor point for the spring system, but provides the means to equally share the
vehicle load to the axles.
To allow the high articulation that the 800 Series suspension provides, the walking
beams MUST be free to move a total of 1.25” (32 mm;.) fore and aft, and .25”
(6 mm.) side to side when the vehicle is on level ground and loaded.
The walking beams have two wear points, at the contact between the beam ends
and the axle saddles. The rate of wear at these points will vary depending on the
operating conditions, axle loading, and distance traveled.
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. 1 Appendix “C” Engineering Bulletin 8905.
Lower flange wear requires the accurate measurement of lower beam flange
thickness. Measurements taken at the flange edges are not an accurate indication
of beam wear see Fig. 8 and may lead to unnecessary beam repair/replacement.
Inspection of the beam ends may be done without removing any major parts using
the following steps as a guideline.
STEP 1 - If possible, power wash the beam end. As a minimum brush the area
with a hard bristle brush to remove road dirt accumulations.
STEP 2 - Chock the front tires to prevent the vehicle from moving. Lift the rear
of the vehicle, support the frame on stands so as all the weight is just taken off the
suspension, and the beam ends are off the saddles.
NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity
to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE
VEHICLE WHEN SUPPORTED ON LIFTING DEVICES.
STEP 3 - Maneuver the beam so as the wear area thickness on the bottom face,
may be determined using either a micrometer or a vernier caliper. Measure the
thickness at the wear area, and a non worn area. See Fig.8. The wear allowance is
the difference between thickness and MUST not be any greater than .062” (l.5mm.)
NOTE: All measurements should be taken 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” (1.5mm.) allowable, a Chalmers
supplied wear plate MUST be installed. Contact Chalmers for details.
Repair of the walking beam entails the use of electric arc welding and MUST be
performed by a qualified shop. See Appendix “C” Engineering Bulletin 8904 and
8905 for repair installation instructions and guidelines.
Replacement of the walking beams may be done in any shop without the use of
special tools using the following steps as a guide:
STEP 1 - If possible, power wash the 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.
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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 VEHI-
CLE WHEN SUPPORTED ON LIFTING DEVICES.
STEP 4 - Remove the spring plate, spring and restrictor can following Steps 3 and
4 in Section 4.5
STEP 5 - Remove the upper, and if necessary, the lower torque rod from the rear
most axle following Step 4 outlined in Section 4.3
NOTE: Tag or mark each torque rod so as each rod may be replaced in the exact
position it came off.
STEP 6 - Roll the rear axle back so as the beam end is free of the saddle. Raise the
free end up and slide the beam back to remove from suspension.
STEP 7 - Install the replacement or repaired beams by sliding the beam ends into
the respective saddles on the front axle. See Fig.9. Roll the rear axle forward and at
the same time, slide the rear beam ends into their respective saddles.
STEP 8 - Replace the rear axle upper and lower torque rods following Step 9
through 11 in Section 4.3.
STEP 9 - Replace the spring plate, spring and restrictor can following Step 6 in
Section 4.5
TABLE 4
Under normal operation, the Chalmers rubber springs do not require periodic
maintenance or replacement. Minor scrubbing from the restrictor can and
attachment fasteners is normal. The springs also lose a little in overall height due
to compression set. This reduction in height occurs in the first few loads, making
an in-service spring shorter than a new spring.
To reduce the chances of prematurely replacing a good spring, the following steps
should be used when inspecting all Chalmers rubber springs
STEP 1 - If possible, power wash the restrictor can spring area. As a minimum,
brush the area with a a hard bristle brush to remove road dirt accumulations.
STEP 2 - Chock the front tires to prevent the vehicle from moving. Lift the
rear of the vehicle, support the frame on stands so all weight is just taken off the
suspension.
NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity
to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE
VEHICLE WHEN SUPPORTED ON LIFTING DEVICES.
STEP 3 - 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.
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4.13 RUBBER SPRING REPLACEMENT
Replacement of Chalmers rubber springs may be achieved easily and quickly in any
shop, without the use of special tools, using the following steps as a guide.
STEP 1 - If possible, power wash the restrictor can spring area. As a minimum,
brush the area with a hard bristle brush to remove road dirt accumulations.
STEP 2 - Chock the front tires to prevent the vehicle from moving. Lift the rear
of the vehicle, support the frame on stands so all weight is just taken off the
suspension.
NOTE: All stands and lifting devices MUST be of sufficient strength and rigidity
to safely support the vehicle. DO NOT WORK AROUND OR UNDER THE
VEHICLE WHEN SUPPORTED ON LIFTING DEVICES.
STEP 3 - Remove the two 3/8” NC fasteners holding the lower spring plate to the
beam. Discard the fasteners. Pull the lower spring plate, spring and restrictor can,
as one assembly outward off the beam. See Fig.5.
NOTE: On 54.0” spread suspensions, it may be necessary to remove either the front
or rear tires to allow spring assembly removal.
STEP 4 - Separate the restrictor can, spring and lower spring plate. Discard the
rubber spring. Using a wire brush or scraper clean all rust, scale and road dirt
accumulations from the spring plate. Clean out the center 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 center spring hole. Place the restrictor can over the spring. Make sure the
can center locator is in the center spring hole. See Fig.5.
STEP 6 - Lift and place, as one assembly, the lower spring plate, spring and
restrictor can onto the beam. Line up the two 3/8” fastener holes.
STEP 7 - Install and tighten the new 3/8” NC spring plate fasteners. Torque to 35
ft.lbs. See Table 2.
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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 center
and axle operating planning angle. They are factory set and play NO part in the
alignment process. See Fig.4.
The four (2 per axle) bottom torque rods set the axle spread, axle operating
angle, and axle alignment. These rods are the ONLY means of making periodic
adjustments for axle alignments. See Fig.4.
The Chalmers 800 Series Suspension allows for the precision alignment of each
axle by the use of fine threads cut into the bottom torque rod tubes. These rods
incorporate left and right hand cut threads on the same tube, thus by rotating the
tube, the rod length may be increased or decreased (within the limit of the rod)
to achieve the desired alignment.
To accommodate all suspension capacities, Chalmers uses two sizes of torque rods
and tubes. See Table 5. and Fig.11.
TABLE 5
Prematurely Loose or Worn Bushings (Chemical Attack, Petroleum Products or Worn Bushings
Used in Installation or Cleaning)
Remove all traces of petroleum products and re-bush.
See Sections 4.2 & 4.3.
Adjustable Torque Rod Tube (Eye Pinch Bolts Not Torque Checked)
Pull Out or Back Off Replace torque rod and torque check pinch bolts. See Table 2.
Walking Beam Touching Triangular Frame (Worn or Loose Upper Torque Rod Bushings)
Re-Bush upper torque rods, See Sections 4.2 & 4.3.
(Tire Pressure)
Check tire pressure and inflate to manufactures specification.
(Tire Pressure)
Check tire pressure, balance, and inflate to
manufacturers specifications.
(Damaged Spring)
Replace spring. See Sections 4.12 & 4.13.
(Damaged Spring)
Replace spring. See Sections 4.12 & 4.13
(Damaged Spring)
Replace spring. See Sections 4.12 & 4.13
(Worn Bushings)
Re-bush. See Sections 4.2 & 4.3.
(Damaged Spring)
Replace spring. See Sections 4.12 & 4.13.
TABLE 6
ITEM PART NO. SPIGOT WEAR LIMIT FOR WEAR LIMIT FOR OVERSIZE
STANDARD BUSHING BUSHING
*SERVICE BUSHING
WEAR MEASUREMENT
To determine wear take two measurements 90 deg. apart “A-A” and “B-B” as shown, or measure over
visible wear area.
The smaller of the two dimensions is to be taken as the wear limit. See Table for values.
NOTE: If Spigot is below min. dimension shown in Oversize Table, contact Chalmers for guidelines.
#2 Joint
800 Series Tandem Truck 46,000
& 50,000 lbs. capacity.
#1 Joint #0 Joint
800 Series Tandem Truck 40,000 lbs. 800 Series Tandem Truck 40,000 lbs.
capacity - after Jan. 1/93. capacity - before Jan. 1/93.
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APPENDIX “A”
IMPORTANT: Inspect (Part No. 260002) when: rebushing, installing new hardware or
when repeated loosening of the hardware occurs.
To Inspect:
Remove cap from joint, remove all dirt, rust, oil and grease from bolt head contact
area, surface “A”.
2. Prior to any installation work, support the vehicle on stands, apply brakes and block
wheels.
3. Prior to any welding, read all general notes and welding processes in Sections 3.0,
4.0, 5.0 & 6.0 of Engineering Bulletin #8905.
6. Clamp wear plate #700313 to bottom flange of beam. Make sure plate is located
centrally on flange and is a good profile fit to flange. If required, slightly grind to
obtain this.
8. Remove clamps. Weld plate to flange as shown building weld to 1/4” minimum
5/16” maximum fillet.
10. Reinstall beam into suspension. Check all bolts for correct torque.
See technical Service Bulletin #8108.
8933RB.BUL
CHALMERS SUSPENSIONS
38 INTERNATIONAL INC.
1.0 Scope:
1.1 This procedure shall be used when repairing and welding Chalmers
Suspensions International Inc. walking beam ends.
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 no 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.
3.1 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.
4.7 COVER GAS - use welding grade C02 cover gas (Minimum Dew Point - 50),
or 95Ar-5C02.
6.0 Inspection:
6.1 Visually inspect every completed row.
CHALMERS SUSPENSIONS
INTERNATIONAL INC. 41
7.0 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 Check the bottom flange of the beams to be repaired. If a beam does not have
wear plates #700313 attached, install them at this point. See Technical Service
Bulletin #8904.
7.7 Grind or air-arc out the crack areas. Do not cut into the flanges.
7.8 Reweld beam end web and stop plates. Build welds to 1/4’ minimum, 5/16”
maximum fillets.
7.9 Clamp 3/8” x 1-7/8” x 3-1/2” end web reinforcement plate to end web (it may
be necessary to grind the plate to obtain a good fit to end webs). Tack weld in
place. Remove clamp and finish weld, building weld to 1/4” minimum, 5/16”
maximum fillet.
7.11 Reinstall beams into suspensions. Check all bolts for correct torque. See
Technical Service Bulletin #8018.
FIG. 1
CHALMERS SUSPENSIONS
42 INTERNATIONAL INC.
APPENDIX “D”
IMPORTANT
Failure to follow these instructions may result in
separation of the torque rod during operation of
the vehicle. This may cause loss of control and
vehicle crash.
The subject torque rods use two (2) pinch bolts to secure the torque rod end to the tube
(see Fig. 1). These bolts must be tightened sequentially until proper torque value is
obtained on both bolts. It is recommended that 1/2” NC phosphate and oil grade 8 bolts
and type “G” stover nuts be used. When Chalmers hardware is used the correct torque
specification is 65 ft. lbs.
If the torque rods have been operated in a loose condition, the threads may be worn
such that clamp load cannot be restored by retorquing the bolts and nuts. A method of
determining if adequate clamp load has been maintained it so measure the gap at the
torque rod as shown in Fig. 2. If the gap is .150” or less, the torque rod has sufficient
clamping load. If the gap is between .150” and .170” we recommend that the hardware
be replaced and tightened to the correct torque specification. If the gap is over .170”
the bolts should be removed, the pinch tabs separated using a chisel as a wedge and the
inspected for wear. If a visible raised portion of the thread is evident in the area along
the gap, the tube has been worn and should be replaced. If there is no evidence of wear,
replace the hardware and tighten to the correct torque specification.
This warranty covers replacement or repair, at our option, of components which our
inspection shows to be defective only, and shall be the sole remedy available to any party
who buys the components or a vehicle in which they are incorporated. Chalmers
Suspensions International Inc. shall not be liable for loss of time, manufacturing costs,
labour, material, loss of profits, or consequential damages, direct or indirect, because of
defective product.
Time Distance
Component (Months) Miles/Kilometers % Allowed
Warranty Exclusions
5. Loss of time, income, manufacturing costs, labour, material, loss of profits or conse-
quential damages, direct or indirect, caused by defective products.
8. Replacement of defective parts with parts other than those provided by Chalmers.
Except for the above warranty, Chalmers Suspensions International Inc., make no
express or implied warranties and no warranty of merchantability or fitness for particular
purposes. No person is authorized to give any other warranties or to assume any liabili-
ties on Chalmers’ behalf.
To the extent any provision of this warranty is in contravention of the Law of any juris-
diction, such provision shall be inapplicable in such jurisdiction, and the remainder of
the warranty shall not be affected thereby.
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