Trailer Axles Installation and Operation Manual Trailer Axles

TRAILER AXLES INSTALLATION AND OPERATION MANUAL TRAILER AXLES

Delivering Suspension Solutions

Delivering Suspension Solutions For more information, call 800.445.0736 11621.SLDDRW 4/28/2009 8:36 AM

WELD PROCEDURE FOR MONO PIVOT BUSHING TYPE ARMS Welding Procedures Preparation Warning ! Clean welds between passes and incorporate tacks REFER TO ES006 FOR ALIGNMENT TO AXLE into the first pass on the tacked side. Fill weld craters and 1. The surface must be free of paint, water, avoid undercuts and cold laps over welds. and other contaminants where welding is to occur. Welds should not be started or stopped at the end of the weld pass. 2. Suspension parts must be at least 60°F. * Normal They should stopped and started away from the ends as shown in Figure 7. recommendations is to preheat Do not wrap the corners of the axle seat while welding. 100-300 degrees F. 1. Three passes are required on each area where the axle is welded to the arms. * Note: Some axle manufacturers recommend preheating Figure 6 shows the size of the weld of each pass. the axle before it is welded. Consult the axle 2. Start welding in the sequence shown in Figure 7 at the rear side where the axle manufacturer for recommended guidelines on and seat meet . Make all first pass welds at all areas before proceeding to the welding to the axle. second pass. 3. Welding needs to be done in a flat horizontal position. 3. Figure 7 also shows the length of weld for both overslung and underslung models.

Welding Axle to Suspension WELD PROCEDURE FOR COMMON: Weld Specifications

Caution ! The welding procedures must be followed carefully to avoid damage to the axle and suspension which could cause an accident and or serious personal injury. 44 TA250/300 TOP MOUNT

TA250/300 UNDERSLUNG

AL2300 DESCRIPTION: AXLE SEAT WELDING PROCEDURE

SHEET: 2 OF 2 DATE: SCALE: DRAWN BY: SIZE: DRAWING NO: 04/22/09 1:8 tgreaves B 11621 Table ofContents WC Weld ProcedureWC Weld Recommendations For WheelEndLubrication 24 Wheel Bearing Adjustment Procedures Self-Adjust and Manual BrakeAdjuster Removal,Installationand maintenance Fastener Torque Specifications Axle Lubrication Model WCP Brake PartNumber X-Reference 16.5” Model WCNBrakePartNumber X-Reference 16.5” Model WCNBrakePartNumber X-Reference 12.25” Axle Options Air Chamber Spacing Brake Lining Certification Model WCP Model WCN WC AxlePart Numbering Guide WC AxleApplicationGuide 1 REV 5/24/2011 Literature #W&C207 35 21 3 2 43 23 20 31 22 16 19 17 10 4 18

G. : 4/28/2009 8:36 AM O AXLE N

G STAR T N I O WELD I N L W C T 11 62 1 DR A PASS #1 PR IO R CONSULT F 2 : EACH PASS. Z E I B E S WELDED TO AXLE BE 2

1 F : 1 O LE :

PAS S PAS S PA G 1 2 3 SC A SPEC S EE T: 1.0 0 H ARM/SEAT S G 1 N ONLY : I THE PROPER POSITION WITH Y B PAS S D

G. SEE 1 N L N W L E C O DR A W R IG URE : : N F G. OD EL : - O 5 I M SS Y

PROCEDURE T 9 A N

Watson & Chalin Axle Application Guide O WELD I N P SE A T O S 1 I AXLE U S 1.0 0 0 E T O I THERS N IN FIGURE 4. THE ELECTRODE SHOULD BE : ROUND V - PAS S 03 / E T E R 2

Bearing Capacity A P AX L DE SCR I PAS S PAS S SUS PE N D 1 Axle Bearings 3 O WELD I N ) TO R O D (lbs/Kg)* PR IO R T L 1/2 T E S

F A E O 6 L R THEN PASS 2 AND 3 ON EACH SEAT IN SERIES. 6 C N N

1 A F O A Outer Cup HM212010 WELD WCN N 0 / O S L . A M 1 I A 1 U R 200

CT I E G PR IO R L A N EP T O Outer cone HM212049 DE C R A C T F F PRIOR TO WELDING. F X E

25000/11350 ( FOR 60 Inner cup HM218210 60 I RES 60 - D E T: S

T H G - I - - M O F M O F E Inner cone HM218248 PARALLEL AND SQUARED IF ASSEMBLED. 2

W DEP T FFE C RE Q U A O TH AXLE SE A TS , IM U Outer Cup HM518410 IM U

WCP B MAX AXLE STAR T

SEQUENCE 1 SHOULD BE PERFORMED ON BOTH AXLE SEATS PRIOR TO AXLE SEATS TO BE CLAMPED SECURELY IN APPLY WELDS IN THE SIZES AND SEQUENCE SHOWN FIRGURE 1, 3. THE WELDING RODS SHOULD CONFORM TO AWS GRADE E-7018 (OVEN-DRIED) AXLE TUBE AND SEATS MUST BE CLEANED. DO NOT WELD AXLES WHEN ARE COLD. NORMAL PREHEAT S FIGURE

E L F C E T Outer cone HM518445 FOR D O SEE ...... E 26000/11800 N --MERITOR REQUIRES AXLE TUBE AND HARDWARE BEING AXLE MANUFACTURER IF NECESSARY. -- IM T --SUDISA REQUIRES AXLE TUBE AND HARDWARE BEING WELDED TO BE MI N THE CORNERS SHOULD BE WRAPPED. CLEAN WELD BETWEEN EACH PASS. --DANA REQUIRES AXLE AND MATING BRACKETS MUST BE 60 6 NOTES: MI N 5 APPLY WELDS IN AREAS SHOW CONTINUING WITH PASSES 2 AND 3. THE SEQUENCE SHOULD BE O N 1 ARMS IF OTHER MANUFACTURER'S AXLE IS USED, CONSULT THEM PRIOR TO WELDING, FOR PREHEAT SPECIFICATIONS. BACKED UP TO FILL IN THE FILLET CRATER AT END OF 2 OR COMPARABLE. USE COMPARABLE WIRE IS USING MIG WELDER. 3 4 RECOMMENDATIONS ARE BETWEEN 100 AND 300 DEGREES F. E

Inner cup HM518410 D

)

N ( O Inner cone HM518445 I S N ESIS AREA E H M I T D N

E E R C WELD ACCEPTABL E X X A A A N M M Recommendations: E

P : R E E 2.0 0 1.5 0 T F T IN E O AREA! O R N T 1- Follow the Watson & Chalin “Normal Service” Capacity chart to select an axle for applications IN N S

AREA! O O N S

running a majority of time on highway travel with “SPRING SUSPENSION” installed on it. D WELD TH I O D WELD TH I 2- When the applications involves running a significant amount of off-road miles, or on exceptionally PASS

rough roads - select the next heavier tube wall than was identified on the applicable Watson & Chalin 3 RD M P TH I

Capacity chart. O TT O 3.0 0 4.0 0 T .5 0 O IG URE 2 F IG URE B 3- When installing the axle on air suspensions or high torsion single pivot suspensions -select the tube F

wall axle than was identified on Watson & Chalin “AIR RIDE SUSPENSION” Capacity chart. 2 E

Minimum wall thickness to be used on an air ride suspension is 0.58” NL Y PA G DO NOT "TEST THE ARC" ON AXLE BEAM SEE O UND AR M/ SEA T AXLE O O T 1/2 R THERS WELD PR O CEDUR E 3 O R R O PAS S F ND 2 F O .5 0 IG URE E F F F F Y F F F B SEC O J J J EF R EF R TE G R ON PA G ARM/SEAT .3 8 3 ONLY 0 6/0 7 0/0 3 03 / 2 /03/0 8 / DAT E 4 2 12/09/0 3 03/01/9 5 12 / 1 0 12/ 1 4/22/200 9 SEE PROCEDURE - 629 9 507 3 - - AXLE EC N 304 2 304 2 304 2 C C C- 530 5 ROUND THERS TO TE D 1/2 R O SPEC S

WELD UPD A R O 4 F O T PASS 6 AND 4 BAC K &

ER I 4 4 TE M NO TE

RKS O FOR & TE TE RST G N O O N F I N N DW O I .3 8 L SUD IS A DANA PT IO N ED ED O S DRAW I

.3 8 RRECTED EW O NT O DESCR I CHAN G ADDED CHAN G N C ADDED I F E A B D C G REV .

43 2 11621.SLDDRW ng er i -XXX

Num b h

id t

73.0” 77.5” 95.5” 71.5” 120 ” 715 ck

r a T 730 955 715 775 120

Drop Drop

t ype

ST Axle Drop Drop Inverted Inverted

6” 9” 6” Straight 9”

I I 9 6

ST 9D 6D

7.5 7 Size x

x 4 7 67 x x

Brake

16.5 15 18 12.25

87 27 54 67

ents 0.5 0.58 0.75 Solid 10mm

kness

5 incre m LE Th i

RS A X 4 5 3 6 1/8 S E Wall B By

NU M SAMPLE

r o type Axle Part Numbering Guide r Spindle type

Spindle

Prop a A45 FF A26/K30 Spindle

N D22

01 04 02 03 Spindle

F P K A N* 75- 0 20- 0 15- 0 15- 0

on & Chalin 67ST 7 27ST 1 67ST 7 67ST 7 x s f i t

a WC Pr e WCN 1

WCN 1 WCP 1 WCP 1 W

42 3

assembly is supported and held steady during Lube change intervals as determined by the manu- removal of the spindle nut and outer bearing. facturer dictate when Level 4 service is performed. This will eliminate the possibility of spindle, bearing or seal damage due to the cocking or slipping NOTE: Manufacturer is defined as the final assem- of the wheel-hub assembly. bler of the product or the particular system supplier.

Model: WCN When reassembling industry standard wheel-ends, ! CAUTION : Care should be taken so the wheel-end assembly is properly supported. assemble per RP 622 and RP 618. Seals and gas- Bearing Group: Inner: HM218248, Outer: HM 212049 kets must be replaced. 5. Remove adjusting nuts. Outside Diameter: 5” - Straight Tube 6. Remove outer bearing. Failed Component Analysis 7. While maintaining proper support to the wheel- Save prematurely failed parts and lube samples for Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n* end or hub, visually check lube level. In a analysis. The lubricant sample collected should be at 0.58” 25,000 lbs (normal service) 22,500 lbs (normal service) semi-fluid grease system, if the lubricant flows least four ounces. A similarly sized new lubricant sample (not previously used) is also required. This 0.75” 27,000 lbs (Normal service) 25,000 lbs (normal service) out of the hub cavity, the hub cavity should be refilled to the 3 o’clock and 9 o’clock level. This will aid in supplier assisted detection and prevention of premature failures. The components’ history of *See capacity charts for details represents 50 percent hub cavity fill. (See Figures 5 and 5A.) usage should also be provided (i.e., vehicle’s vocation, mileage, maintenance records, and history of Track lengths In a semi-fluid grease system, if the grease inspection and repair/replacement of components doesn’t flow, inspect lubricant condition in the such as seals, seal wear rings, lubricant, bearings, 71.5” (standard) etc.). 77.5” (standard) hub cavity. Go to Level 4 Inspection if abnormal conditions are noted. If no abnormal conditions Other tracks also available (38” to 108”) are noted, add grease until it flows out of the hub OPERATIONAL CONSIDERATIONS FOR

cavity. LUBRICANTS Brakes (Refer to: Brake Lining Certification List) Service interval ranges from 100,000 miles to five 16 ½ x 7” quick change, Q, FMSI-4515E NOTE: If changing grease types or brands, years in over-the-road service, depending on axle 16½ x 7” quick change, Q+, FMSI-4707 contact your lubricant supplier to insure compat- type, manufacturer recommendations, and lubricant ibility. performance. Mineral oil based lubricants have lower 16 ½ x 8 5/8” quick change GP, FMSI-4551 initial costs than synthetics lubricants, but need to be 12 ¼ x 7 ½” quick change DA, FMSI-4692 8. Clean bearing and inspect for wear and changed more frequently in some equipment. When damage. When reassembling industry stan- choosing a lubricant, the fleet needs to consider: ABS dard wheel-ends, assemble per RP 618. • the manufacturer’s recommendation for the Bracket is standard - in the SAE recommended position. axle make and model in service. NOTE: Manufacturer is defined as the final as- • the fleet savings associated with extended sembler of the product or the particular system service intervals. Tire Inflation supplier. • the total cost of the lubricant. Spindle preparation is standard - fits PSI, Tiremax and Airgo hardware Level 4—Wheel-end Disassembly Inspection NOTE: Because seal performance may vary when (Complete System Tear-down) switching lubricants, consult your seal supplier for Hub and Drum Assemblies If any abnormal conditions are found during inspection compatibility concerns. All standard North American “N” type products will assemble to the WCN spindle. Levels 1, 2, or 3, remove wheel-end for inspection.

Parts X- Reference See “Reference Information” section

4 41

NOTE FOR DRIVERS: After making an en route stop, reason for further inspection and appropriate action. walk around the unit and feel the hubs. If there is any WCN 5” O.D. significant differences in temperatures or excessive Raise the vehicle and check for smooth rolling of temperature, contact your maintenance department. wheels. Check for signs of excessive end play in the When feeling hubs for temperature, seasonal influ- wheel-end. This does not include removal of the hub BRGS: HM218248 = HM212049 ences should be taken into consideration. cap.

If wheel-ends are equipped with a sight glass on the NOTE: Leaking grease may not spread over the hub AIR RIDE hubcaps, check to ensure the oil is at the proper fill and brake components as with hubs filled with oil. W&C AXLE CAPACITY RATING SPRING SUSPENSION SUSPENSION level. When inspecting for grease leaks the inspection NORMAL SERVICE (See Notes) must be done very carefully with the aid of a bright TUBE WALL TUBE WALL NOTE: Oil residue may be present at the vent area. beam of light from a flashlight or droplight. This is an indicator that the system is venting properly. THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY) 0.58” 0.75” 0.58” 0.75” This should not be construed as system leakage. NOTE: Some grease seals will purge very small AXLE AXLE AXLE AXLE amounts of grease in normal operation. BEAM BEAM BEAM BEAM SPRING MOMENT CAPACITY CAPACITY CAPACITY CAPACITY Level 2—100,000 miles or Annual Inspection: SPINDLE TRACK SEATS ARM GAWR. GAWR. GAWR. GAWR. For non-driven axles check lubricant level and con- If there is seepage around the hubcap flange area, TYPE (INCHES) (INCHES) (INCHES) (lbs.) (lbs.) (lbs.) (lbs.) dition. If lubricant is contaminated replace old lubri- take appropriate action to eliminate seepage as cant with the same type lubricant. If lubricant condi- directed by your maintenance instructions. WCN 71.5 38 16.75 25,000 27,000 25,000 25,000 tion is good and level is low, fill to the proper level. WCN 71.5 37 17.25 24,320 27,000 24,320 25,000 Check for any signs of leakage at the seal or hubcap If leakage in the seal area is found, remove the wheel WCN 71.5 36 17.75 23,640 27,000 23,640 25,000 gasket areas. Check for oil soaked brake linings. end and replace the hubcap gasket, seal and lubri- WCN 71.5 35 18.25 22,990 26,800 22,990 25,000 cant. Inspect the spindle and bearings for damage WCN 71.5 34 18.75 22,380 26,100 22,380 24,870 For driven axles, check for any signs of leakage at and replace if needed. Anything abnormal requires WCN 71.5 33 19.25 21,800 25,400 21,800 24,230 the seal or axle flange gasket areas. Also check for Level 3 Inspection. WCN 71.5 32 19.75 21,240 24,700 21,240 23,610 leaks at hub fill hole if so equipped. Check for oil WCN 71.5 31 20.25 20,720 24,100 20,720 23,030 soaked brake linings. CAUTION :A clogged vent can damage the wheel ! WCN 71.5 30 20.75 20,220 23,500 20,220 22,480 seal allowing internal pressure build up in the wheel Take appropriate action if leaks or oil soaked brake end. WCN 71.5 29 21.25 19,740 23,000 19,740 21,950 linings are noted. WCN 71.5 28 21.75 19,290 21,440 Level 3—Lube Level Inspection B. GREASE LUBRICATED WHEEL ENDS (Per OEM Recommendation) WCN 77.5 44 16.75 25,000 27,000 25,000 25,000 INSPECTION CRITERIA When using grease in a wheel-end the only method WCN 77.5 43 17.25 24,320 27,000 24,320 25,000 to accurately check the lubricant level is by pulling WCN 77.5 42 17.75 23,640 27,000 23,640 25,000 Level 1—Simple Inspection (Pre-Trip/In-Service) the outer bearing. If using a hard grease, there is no WCN 77.5 41 18.25 22,990 26,800 22,990 25,000 Walk around vehicle and check wheel-ends for obvi- need for a Level 3 Inspection. ous signs of lubricant leakage, such as hubcap WCN 77.5 40 18.75 22,380 26,100 22,380 24,870 gasket and wheel seal areas, grease soaked brake WCN 77.5 39 19.25 21,800 25,400 21,800 24,230 linings. Check for broken or missing components. ! CAUTION : Failure to remove the outer bearing may provide a false lubricant level reading. WCN 77.5 38 19.75 21,240 24,700 21,240 23,610 Any seepage is reason for further inspection and WCN 77.5 37 20.25 20,720 24,100 20,720 23,030 appropriate action. To verify proper lube level the following procedures WCN 77.5 36 20.75 20,220 23,500 20,220 22,480 need to be performed. NOTE FOR DRIVERS: After making an en route stop, WCN 77.5 35 21.25 19,740 23,000 19,740 21,950 1. Before performing any maintenance on the walk around the unit and feel the hubs. If there is any WCN 77.5 34 21.75 19,290 21,440 vehicle take appropriate action to ensure the significant differences in temperatures or excessive NOTES: vehicle is safely secured. temperature contact the maintenance department. 1. Ratings are for spring or air suspensions used in normal service. 2. Remove hubcap, hubcap gasket and inspect When feeling hubs for temperature, seasonal influ- 2. High torsion single point spring suspensions are considered same as air suspensions. hubcap for adequate venting capabilities. ences should be taken into consideration. 3. Verify wheel-bearing end play for conform- 3. For off-road use, find the rating above, then use the next heavier wall. ance to RP 618. 4. Special applications: call Watson & Chalin for technical assistance Level 2—Detailed External Inspection 4. Record end play measurements. (Conducted at PM or at least annually) Check wheel-ends for obvious signs of lubricant leakage, such as hubcap gasket and wheel seal ! CAUTION : Apply the parking brake, if axle is areas, grease soaked brake linings. Any seepage is equipped. This will ensure that the wheel/hub

40 5

temporarily ings 0.005") and thenfillthehubcavity. of and damage. hubcaps Use Hubcap Considerations:HardGrease grease aroundtheadjustingnut(s). being clean While assembly intoposition. damage hub hub Install Hub FillProcedures:Oil 618 andRP622. ers, axle the If Inspection andPreparation tionable due. recommendation axles NOTE: CONSIDERATIONS DRIVEN AXLELUBRICANTWHEELEND special carenottocovertheventwithgrease. coat NOTE: the hubcapshouldbeventedornon-vented. Pre-lubricate Component RP the cones ©2003—TMC/ATA ! ! the lubricant CAUTION CAUTION 622. axle wheel maintain cavity removing shafts, assembly the Replace an with

wheel

are oil added the the with

with appropriate

reservoir. parts. interior the and

For prevent a wheel oil

hub with grease end this

metal clean and

restrict hub end

seal

lubricated.

to push proper additional Lubrication

: : a seal,

the

In Failure all is For oil. with grease-filled Recommended components may

seals, dial and surfaces is

oil and lubricant hub supported, of

gear contaminants into disassembled, inner Use before axle or detail

bath the

lubrication the contribute bearing indicator. tamper-proof, spindle cap

prevent as to position

oils lifting information

seal flange spindle systems,

and documented lubricate procedures, with

is of installation. from

used, wheel supplier cups,

including fill the equipment threads. outer

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refer a necessary and

all grease. type

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accidentally Grease determine and seal

care and RP to to

cavity pack coating Follow circulation in all bearings,

correctly TMC align all position 622. bearing bearing to the

used inspect fasten- failure. These driven to ques-

bear- TMC resi- RP with Use hub

not will the the RP

Fill

to of in

if 631A—5 39 bearings top that is f be and Oil Install manuf lubricated is NOTE: 622 andRP618.) to Install 0.005") withadialindicator. Maintenance achieve Adjust units The REQUIREMENTS MAINTENANCE debris. Recheck axle reservoir. or The sembly These for inspectionandservicerecommendations. ous gasket ings. Walk Level INSPECTION A. OILLUBRICATEDWHEELENDS fill seepage linings arenoted. Take priate action. lange ! operating always pre-set move level. raised is off CAUTION would inspection signs following through supplied whose Check around appropriate a 1—Simple the the the recommendations wheel and cturer’s Always of

final gaske

the

is the with wheel outer

to a the

with lubricant flanged give of reason

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main :

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system, the directly Manual. grease lubricant CRITERIA

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per strictly Verify

areas, pack of washers tube the eight leakage, ion. if axle check for

completely if missing axle depend leaks criteria end the axle the not to required. TMC’s

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the Clean-up the lange

systems inspection (Pre-Trip/In-Service) shaft during inches the fill on-highway breather end of oil intended opposite

differential. wheel-ends

of the proper or wheel

and the

plug

soaked components. drive on a ends such are RP oil with play proper leaking

drive nuts The for free adjusting the operation.

soaked any manufacturer or

618 intended

ends oil

axle one a for wheel as and hole (0.001" proper

oil of

assembly o axle brake

be new level

use lubricant (See

v t

for or unitized system. o dirt hubcap fill er minute appro- will

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wheel brake in

OEM spills nuts. must obvi- only. a level end.

axle

Any and and

x the RP as- lin- for To be l to e it Maintenance Manual. Verify end play (0.001" to 0.005") with a dial indicator. Before installing the hubcap, apply a coating of grease around the wheel bearing adjustment nut(s).

Hubcap Considerations: Semi-fluid Grease Use an appropriate tamper-proof, vented hubcap. These hubcaps prevent gear oils from being acci-

dentally added to grease-filled wheel ends.

NOTE: Because of the hubcap’s special venting capability and the properties of the semi-fluid grease, do not fill the hubcap with grease.

If a metal hub cap is used, it is necessary to Fig. 5C: Using Template to Hold Lubricant NOTE: coat the interior surfaces with a film of grease. Use The grease fill amount should be to a 3 o’clock and special care not to cover the vent with grease. 9 o’clock level. This represents 50 percent hub cavity fill. (See Figures 5A and 5B.) Hub Fill Procedures: Hard Grease Before installing the hub, pack grease into the hub NOTE: A template may be used to hold the lubricant cavity. Fill the circumference of the hub cavity using in place while filling the hub cavity. (See Figures 5 the bearing races as the proper level guide. (See and 5C.) Figure 6.)

Use lifting equipment to align the hub assembly with CAUTION : Make sure that there are no air-pock- ! the spindle taking care to not damage the seal and ets trapped under the grease. If pumping equipment spindle threads. Push the hub assembly into position. is used, ensure the pump does not aerate the grease. Aeration of the grease may result in underfilling. Install the outer bearing, washers and adjusting nuts. Adjust wheel bearings per TMC’s RP 618 or OEM Install the outer bearing, washers and adjusting nuts. Maintenance Manual. Verify end play (0.001" to Adjust wheel bearings per TMC’s RP 618 or per OEM

Fig. 6: Lubrication Fill Greases (Nos. 1,2, & 3)

38 7

: If grease packing is done by hand, appropriate protection — such as gloves and cloth- WCN6D ing — should be worn to minimize skin contact with the grease. 6” DROP CENTER AXLE BEARINGS: HM218248 + HM212049 Mandatory Grease Area WATSON & CHALIN CAPACITY Air Ride SUSPENSION ! CAUTION : Overfilling or under filling a wheel hub RATING for AIR RIDE SUSPENSIONS TUBE WALL with lubricant may result in premature component failure. THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY) 0.58” 0.75 MOMEN Hub Fill Procedures: Semi-fluid Grease SPRING T ARM AXLE BEAM AXLE BEAM If tires are not mounted, install the hub on the spindle. SPINDLE TRACK SEATS (INCHE CAPACITY CAPACITY Fig. 4: Packing of Bearing Cone Take care to not damage the seal. Use lifting equip- TYPE (INCHES) (INCHES) S) GAWR. (lbs.) GAWR. (lbs.) ment to align the hub assembly with the spindle WCN 71.5 38 16.75 22,500 25,000 gasket, and all questionable parts. For detailed pro- taking care to not damage the seal and spindle cedures, refer to TMC RP 622. WCN 71.5 37 17.25 21,850 24,320 threads and push the hub assembly into position. WCN 71.5 36 17.75 21,230 23,640 NOTE: If retrofitting an oil or grease system with a WCN 71.5 35 18.25 20,650 22,990 With the hub supported, before installing the outer semi-fluid grease, be sure to note the need for WCN 71.5 34 18.75 20,100 22,380 bearing cone, begin filling from the bottom of the hub special cleaning instructions, fill procedures and WCN 71.5 33 19.25 19,580 21,800 cavity. Top-off by placing the pump nozzle above the equipment (i.e., vented hubcap). spindle, and continue pumping grease into the hub WCN 71.5 32 19.75 19,080 21,240 cavity. (See Figure 5.) WCN 71.5 31 20.25 18,610 20,720 Component Lubrication WCN 71.5 30 20.75 18,160 20,220 Pack the inner and outer wheel bearing cones full with grease. Work the grease into the bearing in the WCN 71.5 29 21.25 17,730 19,740 direction of the arrow shown in Figure 4 by machine

or hand such that the grease goes under the bearing WCN 77.5 44 16.75 22,500 25,000 cage toward the cone rib and roller ends. WCN 77.5 43 17.25 21,850 24,320 Cup Small Inside Diameter WCN 77.5 42 17.75 21,230 23,640 For corrosion prevention, place a light film of grease CONE WCN 77.5 41 18.25 20,650 22,990 on all metal components, including the hubcap. Wipe WCN 77.5 40 18.75 20,100 22,380 off the excess grease. Install the wheel seals as ROLLER WCN 77.5 39 19.25 19,580 21,800 described in TMC RP 622. CUP WCN 77.5 38 19.75 19,080 21,240 CAGCUPSE CAUTION WCN 77.5 37 20.25 18,610 20,720 ! : Failure to lubricate bearing correctly and maintain proper lubrication may result in bearing WCN 77.5 36 20.75 18,160 20,220 Fig. 5B: Tapered Bearing Nomenclature damage. For detailed procedures, refer to TMC RP WCN 77.5 35 21.25 17,730 19,740 618 and RP 622.

NOTES: 1. Ratings are for air suspensions used in normal service. 2. For off-road use, find the rating above, then use the next heavier wall. 3. Special applications: call Watson & Chalin for technical assistance

Apply Grease Around Adjusting Nut

Fig 5A: Lubrication Fill Fig. 5: Semi-Fluid Grease Top Off Procedure Semi-Fluid Grease (No. 00)

8 37

Fleet managers should also reference original equipment manufacturer (OEM) maintenance and service manuals as appropriate.

NON-DRIVEN AXLE LUBRICANT CONSIDERATIONS Non-driven wheel ends can be lubricated effectively with either oil or grease, depending on the fleet application. Both lubricating substances use oil as the lubricating medium. (Refer to RP 624, Lubricant Fill to Fundamentals for details.) oil level line

A. Non-Driven Oil-Lubricated Wheel Ends

Inspection and Preparation Clean and inspect the wheel end components including all bearings, hubcaps, hub and bearing cups, Fig. 3: Lubrication Fill Oil (Static) axle spindle, and fasteners, removing all contaminants and lubricant residue. Replace seal, hubcap Hubcap Considerations: Oil gasket, and all questionable parts. For detailed pro- Select the proper vented, bolt-on or threaded hubcap cedures, refer to TMC RP 622. for the application and follow hubcap suppliers’ instructions for proper attachment to the wheel hub. Fill Component Lubrication wheel end assembly through the fill port with the Pre-lubricate the inner and outer wheel bearing same oil. Allow time for the oil to seep through the cones with clean lubricant of the same type used in outer bearing and fill the hub cavity. Continue to add the hub assembly. oil until the oil reaches the oil fill line as indicated on the hubcap. (See Figure 3.) ! CAUTION : Failure to lubricate bearing correctly, and maintain proper lubrication, may result in bear- NOTE: For hubcaps with side fill plugs, do not allow ing damage. For additional information refer to TMC the oil to go past the centerline or vent hole. RP 618 and RP 622. ! CAUTION : Overfilling or under filling a wheel hub ! CAUTION : In oil bath systems, do not pack bear- with lubricant may result in premature component ings with grease before installation. Grease will failure. temporarily restrict or prevent the proper circulation of lubricant and may contribute to wheel seal failure. Install center fill or side fill plug. Torque side fill plug to hubcap manufacturer’s specifications. Clean-up Hub Fill Procedures: Oil any over spills that would give the appearance of a Install the wheel seals as documented in RP 622. leaking hubcap. Apply lubricant to the bearing journals and bearing cones. Use the same lubricant that will be used to B. Non-Driven Grease-Lubricated Wheel Ends lubricate the system. This will help inhibit fretting corrosion and make assembly easier. Use lifting NOTE: Semi-fluid greases are NLGI 000 and 00. equipment to align the hub assembly with the spindle NLGI 0 is a soft grease. All three grades listed above taking care not to damage the seal and spindle are treated as semi-fluid greases in this RP. Hard threads. While the hub is supported/suspended, fill greases are defined as NLGI 1, 2, and 3 consisten- the hub cavity with clean oil and push the hub into cies in this RP. position, or push the hub into position and then fill the hub cavity. Inspection and Preparation Clean and inspect the wheel end components includ- Install the outer bearing, and adjusting nut systems. ing all bearings, hubcaps, hub and bearing cups, Adjust wheel bearings using TMC RP 618 or OEM axle spindle, and fasteners, removing all contami- Maintenance Manual. Verify end play (0.001" to nants and lubricant residue. Replace seal, hubcap 0.005") with a dial indicator.

36 9

Recommended Practice

Model: WCP RP 631A VMRS 018

Bearing Group: Inner: HM518445, Outer: HM518445 RECOMMENDATIONS FOR WHEEL END LUBRICATION

Outside Diameter: 5” – Straight Tube PREFACE The following Recommended Practice is subject Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n* Hub to the Disclaimer at the front of TMC’s Recom- 0.58” 25,000 lbs (normal service) 22,500 lbs (normal service) mended Maintenance Practices Manual. Users Outboard Seal 0.75” 27,000 lbs (Normal service) 25,000 lbs (normal service) are urged to read the Disclaimer before consid- Bearing * See capacity charts for details ering adoption of any portion of this Recom- Adjusting Nut mended Practice. Outside Diameter: 5 ¾” Straight Tube PURPOSE AND SCOPE Inboard Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n* The purpose of this Recommended Practice is to Hubcap Bearing 0.39” 25,000 lbs (normal service) 25,000 lbs (normal service) offer equipment users recommendations and operational considerations for selecting lubri- Track lengths cants for use in wheel end applications. Lubricant 71.5” (standard) Cavity Wheels 77.5” (standard) This Recommended Practice applies to Class 3- 8 trucks, buses, tractors, and trailers designed Other tracks also available (38” to 108”) Fig. 1: Non-Drive Wheel End for on-highway applications.

Brakes (Refer to: Brake Lining Certification List) This Recommended Practice applies to only “tradi- Other relevant TMC Recommended Practices 16 ½ x 7” quick change, Q, FMSI4515E tionally” equipped axles and hubs. This Recom- include: 16 ½ x 7” quick change, Q+, FMSI4707 mended Practice defines “traditionally” equipped • RP 624, Lubricant Fundamentals. 16 ½ x 8 5/8” quick change GP, FMS axles and hubs as wheel ends equipped with two • RP 709, Hubcap Standardization — Bolted- I4551 12 ¼ x 7 ½” quick change DA, FMSI4692 single row, widespread, tapered roller bearing as- On Type. semblies which are manually adjusted.

ABS This Recommended Practice addresses Bracket is standard in the SAE position two categories of wheel ends: driven and non-driven. Non-driven wheel ends include Tire Inflation Brake steer, dolly, trailer, pusher and tag axles. Spindle preparation is standard fits PSI, Tiremax and Airgo hardware Drum (See Figures 1 and 2). Hub and Drum Assemblies Hub All standard North American “P” type products will assemble to the WCP spindle. The lubricant used in the wheel ends can be Outboard Parts XReference either petroleum-based or synthetic- Bearing Seal See “Reference Information” section based oils or greases. Adjusting Nuts REFERENCE Drive Axle For additional information on wheel bearing Shaft adjustment, installation and maintenance, refer to TMC: Gasket Spindle • RP 618, Wheel Bearing Adjustment Oil Cavity Procedures. Inboard • RP 622, Wheel Seal and Bearing Bearing Removal, Installation, and Mainte- Wheels nance. Fig. 2: Drive Axle Wheel End

10 35

TABLE 1

WHEEL BEARING ADJUSTMENT PROCEDURE

STEP 1: Lubricate the wheel bearing with clean axle lubricant of the same type used in the axle sump or hub assembly. Note: Never use an impact wrench when tightening or loosening lug nuts or bolts during the procedure.

INITIAL INITIAL FINAL BACK OFF JAM NUT TORQUE ACCEPTABLE ADJUSTING BACK OFF ADJUSTING AXLE THREADS FINAL NUT TORQUE END PLAY NUT NUT TYPE PER INCH BACK OFF SIZE SPECIFICATIONS TORQUE TORQUE STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8

12 1/6 Turn * Install Cotter Pin to Lock Axle Nut in Position 18 1/4 Turn * Steer (Front) Non-Drive 14 Less Than 200-300 lb•ft 0.001"-0.005" 1/2 Turn 2-5/8" (271-407 N•m) (.025-.127 mm) 200 lb•ft One 50 lb•ft (66.7 mm) 18 (271 N•m) Full (68 N•m) While While Turn Dowel Rotating Rotating 300-400 lb•ft As Measured 12 Type Wheel Wheels (407-542 N•m) Per Procedure Washer Drive 1/4 Turn With Dial Tang Type 200-275 lb•ft Indicator 16 Washer ** (271-373 N•m)

12 2-5/8" 300-400 lb•ft Trailer 1/4 Turn (66.7 mm) (407-542 N•m) and over 16

* If dowel pin and washer (or washer tang and nut flat) are not aligned, remove the washer, turn it over, and reinstall. If required, loosen the inner (adjusting) nut just enough for alignment. ** Bendable type washer lock only: Secure nuts by bending one wheel nut washer tang over the inner and outer nut. Bend the tangs over the closest flat perpendicular to the tang.

34 11

the inner adjusting nut the equivalent of 1/2 of an the inner and outer nut. Bend the tangs over the alignment hole of the washer, or reversing the closest flap perpendicular to the tang. See Fig. WCP 5” O.D. alignment washer, and reinstalling it onto the spindle. 2. BRGS (2) HM518445 Reassemble and re-torque the outer (jam) nut. Refer to Table 1 for torque values. Verify end play CAUTION: Before operating the unit, the wheel with a dial indicator. hub cavities and bearings must be lubricated to TUBE WALL prevent failure. For final wheel end assembly AXLE CAPACITY RATING NOTE: Bendable-type washer lock only: Secure refer to TMC RP 622. NORMAL SERVICE (See Notes) Spring Suspension Air Ride Suspension nuts by bending one wheel nut washer tang over

THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY) 0.58 “ 0.75 “ 0.58 “ 0.75 “ SPRING MOMENT AXLE BEAM AXLE BEAM AXLE BEAM AXLE BEAM SPINDLE TRACK SEATS ARM CAPACITY CAPACITY CAPACITY CAPACITY TYPE (INCHES) (INCHES) (INCHES) GAWR. (lbs.) GAWR. (lbs.) GAWR. (lbs.) GAWR. (lbs.) SINGLE NUT ADJUSTMENT TANG-TYPE LOCK ADJUSTING NUT SPINDLE WASHER-TYPE WCFP” “ 71.5 38 16.75 25,000 27,000 25,000 25,000 ADJUSTING NUT 37 17.25 24,320 27,000 24,320 25,000 Bend tangs Wheel bearing perpandicular 36 17.75 23,640 27,000 23,640 25,000 Adjusting adjusting nut 35 18.25 22,990 26,800 22,990 25,000 nut to closest (inner) Nut flat 34 18.75 22,380 26,100 22,380 24,,870 lock 33 19.25 21,800 25,400 21,800 24,230 32 19.75 21,240 24,700 21,240 23,610 31 20.25 20,720 24,100 20,720 23,030 30 20.75 20,220 23,500 20,220 22,480 Dowel pin 29 21.25 19,740 23,000 19,740 21,950 Wheel bearing Outer adjusting Spindle washer Cotter nut WCFP” “ 77.5 44 16.75 25,000 27,000 25,000 25,000 pin “D” Washer nut (inner) Outer nut 43 17.25 24,320 27,000 24,320 25,000 42 17.75 23,640 27,000 23,640 25,000 “D” Type “Tang” Type “Dowel” Type 41 18.25 22,990 26,800 22,990 25,000 40 18.75 22,380 26,100 22,380 24,870 39 19.25 21,800 25,400 21,800 24,230 Fig. 2: Adjusting Nut Identification and Installation 38 19.75 21,240 24,700 21,240 23,610 37 20.25 20,720 24,100 20,720 23,030 36 20.75 18,160 23,500 18,160 22,480 35 21.25 17,730 19,740 17,730 21,950

WCFP” “ 84 “ 50.5 16.75 22,500 25,000 49.5 17.25 24,320 27,000 48.5 17.75 23,640 27,000 Call Call 47.5 18.25 22,990 26,800 Watson & Watson & 46.5 18.75 22,380 26,100 45.5 19.25 21,800 25,400 Chalin for Chalin for 44.5 19.75 21,240 24,700 technical technical 43.5 20.25 20,720 24,100

42.5 20.75 20,220 23500 assistance. assistance. 41.5 21.25 19,740 23000

NOTES: 1. Ratings are for spring or air suspensions used in normal service. 2. High torsion single point spring suspensions are considered same as air suspensions. 3. For off-road use, find the rating above, and then use the next heavier wall.

12 33

If dowel pin and washer (or washer tang and nut flat) (d) Grasp the wheel assembly at the 3 o’clock and are not aligned, remove the washer, turn it over and 9 o’clock positions. Push the wheel assembly in and Model: WCPX676D reinstall. If required, loosen the inner (adjusting) nut out while oscillating it to seat the bearings. Read just enough for alignment. bearing end play as the total indicator movement.

IMPORTANT NOTE: If end play is not within specification, Never tighten the inner (adjusting) nut for readjustment is required. Bearing Group alignment at this point of the procedure. This Inner: HM518445 may pre-load the bearing and cause premature Step 9: RE-ADJUSTMENT PROCEDURE Outer: HM518445 failure. Outside Diameter: Drop Center & Camel Back Tube: . Excessive End Play 5” 6” drop Step 7: Install and torque the outer (jam) nut. Refer If end play is too loose, remove the outer (jam) nut (8” and 9” drops also available) to Table 1 at the end of this Recommended Practice and pull the washer away from the inner (adjusting) for proper torque values. nut, but not off the spindle. Tighten the inner (adjusting) nut to the next alignment hole of the washer. NOTE: This adjustment allows the wheel to Reassemble the washer and re-torque the outer Tube wall Maximum capacity* rotate freely with 0.001" to 0.005" (0.025 mm to (jam) nut. Refer to Table 1 for torque values. Verify 0.58” (X=’s 5) 22,500 lbs (normal service) 0.0127 mm) end play. end play with a dial indicator. 0.75” (X=’s 6) 25,000 lbs (normal service) *See capacity charts for details Step 8: Verify end play with a dial indicator. Wheel Insufficient End Play end play is the free movement of the tire and wheel If end play is not present, remove the outer (jam) nut assembly along the spindle axis. and pull the washer away from the inner (adjusting) Track lengths nut, but not off the spindle. Loosen the inner (adjust- 71.5” (standard) (a) Make sure the brake drum-to-hub fasteners are ing) nut to the next alignment hole of the washer. 77.5” (standard) tightened to the manufacturers’ specifications. Reassemble the washer and re-torque the outer Other tracks available – please consult Watson & Chalin Sales and Technical support. (jam) nut. Refer to Table 1 for torque values. Verify (b) Attach a dial indicator with its magnetic base to end play with a dial indicator. Brakes the hub or brake drum. 16 ½ x 7” quick change, FMSI4515 FINE TUNING THE ADJUSTMENT 16 ½ x 7” quick change, GP+ (Q+), FMSI4707 (c) Adjust the dial indicator so that its plunger or If, after performing the readjustment procedures, pointer is against the end of the spindle with its line end play is 0.004" - 0.005" (0.102 mm - 0.127 mm) of action approximately parallel to the axis of the range, repeat the appropriate procedures, remov- ABS spindle. See Fig. 1. ing the washer from the spindle, tighten or loosen Bracket is standard in the SAE position

Tire Inflation Spindle preparation for PSI, Tiremax and Airgo is standard.

Cam position Ahead of axle Behind the axle

Cam Length See specific model drawing

Hub and Drum Assemblies All standard North American “P” type products will assemble to spindle. With indicator mounted at bottom Parts XReference Withpush/pull indicator at mounted sides ofat bottomdrum push/pull at sides of drum See “Reference Information” section (a) with tire assembly (b) without tire assembly

Fig. 1: Dial Indicator Set-Up

32 13

Recommended Practice

RP 618 VMRS 018

WHEEL BEARING ADJUSTMENT PROCEDURES

PREFACE adjusting the wheel bearings. Failure to do this The following Recommended Practice is subject to may result in improper wheel bearing adjust- the Disclaimer at the front of TMC’s Recommended ment. Maintenance Practices Manual. Users are urged to read the Disclaimer before considering adoption of REFERENCES any portion of this Recommended Practice. TMC RP 622,Wheel Seal and Bearing Removal, Installation and Maintenance. OBJECTIVE The goal of this Recommended Procedure is to PROCEDURES achieve a verifiable wheel bearing end play of Step 1: Lubricate the bearing with clean axle lubri- 0.001" to 0.005" (0.025 mm to 0.127 mm). cant of the same type used in the axle sump or hub assembly. SCOPE The following service procedures apply to steer, drive, and trailer axle assemblies using conven- IMPORTANT tional double nut or single nut systems. Follow (a) In oil bath systems that rely on differential these service procedures carefully to prevent pre- fill to provide lubricant to the wheel seals, mature wheel end component failure and increase do not pack bearings with grease before seal and bearing life. installation. Grease will temporarily restrict or prevent the proper circulation of ABS (anti-lock braking systems) and traction con- axle lubricant and may contribute to wheel trol systems with wheel end sensing require precise seal failure. bearing adjustment to function properly. (b) Never use an impact wrench to adjust This Recommended Practice details proper service wheel bearings. procedures for D-type, bendable-type, and dowel- type spindle nut washers. Step 2: After the wheel hub and bearings are assembled on the spindle or axle tube, torque the NOTE: For single nut self-locking systems, consult inner (adjusting) nut to 200 lbf• ft (271 N•m) while manufacturers’ instructions. rotating the wheel hub assembly. Refer to Table 1 at the end of this Recommended Practice. If you have a system that differs from what is indicated in this procedure, consult the vehicle Step 3: Back off the inner (adjusting) nut one full manufacturer’s recommended procedure. turn. Rotate the wheel.

WARNING: Never work under a unit supported Step 4: Re-torque the inner (adjusting) nut to 50 by only a jack. Always support the vehicle with lbf• ft (68 N•m) while rotating the wheel hub assem- stands. Block the wheels and make sure the unit bly. Refer to Table 1 at the end of this Recom- will not roll before releasing brakes. mended Practice.

CAUTION: If your axle is equipped with spoke Step 5: Back off the inner (adjusting) nut. Refer to wheels and the rim clamps have been disas- Table 1 at the end of this Recommended Practice sembled to remove the tire and rim assembly, for the proper back-off amount. the tire and rim assembly must be reinstalled and the rim clamps properly torqued BEFORE Step 6: Install the locking washer.

14 31

spring pressure is relieved from the clevis. Work the Style C). The pawl must be installed properly adjusting nut 1/4 turn back and forth while watching and tightened to 15 - 20 ft-lbs after backing off for cam rotation. If you have 1/8 to 1/4 turn of play the adjuster. without the cam rotating, the manual brake should be 2. Apply the brakes several times and observe replaced. Repeat this procedure every 1/4 turn of the whether the adjustment mechanism is rotat- adjusting nut to check the whole gear set. ing in the direction needed to reduce brake chamber pushrod stroke. If the adjusting Self-Adjusting Brake Adjuster Failure Analysis— mechanism does not rotate, the brake ad- If the power stroke is at or more than the maximum juster should be replaced. stroke, measure free stroke and check/inspect the 3. Check back-off torque by rotating the adjust- adjuster components and attaching hardware to ing hex as follows (see Fig. 2): determine if the slack adjuster is operational. • Style A: Minimum 15 ft-lbs counter clock- wise (CCW) FREE STROKE MEASUREMENT • Style B: Minimum 15 ft-lbs CCW Free stroke is the amount of brake arm movement • Style C: Less than 45 in-lbs CCW (pawl required to move the brake shoes against the drum. removed) To measure free stroke, perform the following: • Style D: Minimum 15 ft-lbs CCW 1. With the brakes released, measure from the brake chamber face to the center of the clevis Consult the manufacturer for more information. pin. 2. With a lever, pry the brake adjuster arm until PREVENTIVE MAINTENANCE the brake shoes contact the drum and mea- Every month, 8,000 miles, or 300 operating hours, sure the brake adjuster movement check brake chamber push rod travel;chamber stroke (see Fig. 6). should be in compliance with the maximum allow- 3. The difference between the brake released able adjusted strokes indicated in Table 1, without and applied measurements is the free stroke. the brakes dragging or the pushrod binding. Adjust The free stroke should be 3/8" - 5/8". If the free manual slacks if necessary. Due to different operat- stroke is in the correct range, the out of spec ing conditions, adjustments may be necessary at stroke is due to a foundation brake problem. earlier intervals. Check for missing or worn components, cracked brake drums, or improper lining-to- Every 6 months, 50,000 miles, or 1,800 operating drum contact. If the free stroke is greater than hours, lubricate all brake adjusters and clevis pins recommended, a self-adjusting brake adjuster with manufacturer’s recommended lubricant. Check function test should be performed. for worn clevises, clevis pins, clevis pin bushings, and worn or broken control arm/attaching brackets. SELF-ADJUSTING BRAKE ADJUSTER Failure to replace worn, broken, or disconnected FUNCTION TEST components will increase chamber stroke. Lubrica- 1. Remove the pawl, then rotate the adjusting tion and inspection may be necessary at earlier, mechanism at least one complete turn as if intervals due to different operating conditions. backing off the brake adjustment (see Fig. 2,

30 15

Brake Lining Certifications on Watson & Chalin Axles Tire Spring Auto-Slack Lining Brake size Loaded Country / Manufacturer FMSI # Brake Size Arm Length Rating (lbs) Certification Marerial (inches) Radius Continent (inches²) (inches) (inches) PL133 Fuwa 16.5 x 7 4515E 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121 PL133 Fuwa 16.5 x 7 4515E N/R (1) Type-30 6 12 tonnes (2) Australia ADR Schedule-4, SARN#35665 MB21 Carlisle 16.5 x 7 4515E 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121 PL244 Fuwa 16.5 x 7 4515E 20.6 30-30 5.5 23,000 USA,Canada FMVSS121/CMVSS121 PL133XT Fuwa 16.5 x 7 4707 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121 PL244 Fuwa 16.5 x 7+(3) 4707 20.6 30-30 5.5 23,000 USA,Canada FMVSS121/CMVSS121* 16 PL244 Fuwa 12.25 x 7.5 4692 15 30-30 6 20,000 USA,Canada FMVSS121/CMVSS121

Notes: 1- N/R = Not required for this certification 2- Metric tonnes. 3- 16.5 x 7 is Q+ REV. 2 - 09.28.2009

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TABLE 1 1. Measure from the brake chamber face to the Air Chamber Spacing center of the clevis pin at all wheel locations CHAMBER TYPE VS. MAXIMUM LEGAL STROKE (see Fig. 3). (Inches) AT 90-100 PSI BRAKE APPLICATION PRESSURE 2. Make brake applications until the air reservoir gage reads 90-100 psi. Then have an assis- Chamber Type Maximum Legal Stroke AC tant make a full brake application and hold it. 12 1-3/8" or less 3. Measure from the brake chamber face to the BRAKE SIZE TRACK CL WCN WCP 12 Long Stroke 1-3/4" or less 16 1-3/4" or less center of the clevis pin (see Fig. 4). 12.25 x 7.5” 65 20.75 8.3 16 Long Stroke 2.0" or less 4. The difference between the brakes released 12.25 x 7.5” 71.5 20.75 14.8 N/A 20 1-3/4" or less and applied measurements is the power stroke 12.25 x 7.5” 71.5 21.13 14 N/A 20 Long Stroke 2.0" or less measurement. If the stroke is less than the 12.25 x 7.5” 71.5 23.38 9.5 N/A 24 1-3/4" or less maximum stroke for the chamber size (see 24 Long Stroke 2.0" or less Table 1), the inspection is complete. If the 12.25 x 7.5” 71.5 23.75 8.8 N/A 24 Extra Long Stroke 2.5" or less power stroke is more than the maximum stroke 12.25 x 7.5” 77.5 20.75 20.8 N/A

30 2.0" or less for the chamber size (see Table 1 ), refer to 12.25 x 7.5” 77.5 21.13 20 N/A 30 Long Stroke 2.5" or less the section entitled FAILURE ANALYSIS. 12.25 x 7.5” 77.5 23.38 15.5 N/A 36 2-1/4" or less 12.25 x 7.5” 77.5 23.75 14.8 N/A SELF-ADJUSTING BRAKE ADJUSTER 16 ½ x 7” 71.5 17.52 22.1 22.1 of free stroke. Free stroke less than 3/8" can ADJUSTMENT PROCEDURE AT RELINE 16 ½ x 7” 71.5 20.63 15.9 15.9 cause brake drag. If you can’t maintain maxi- AND INSTALLATION A self-adjusting brake adjuster should be manually 16 ½ x 7” 71.5 21.38 14.4 14.4 mum legal stroke and the free stroke is less 16 ½ x 7” 71.5 23.75 9.7 9.7 than 3/8", contact the brake manufacturer for adjusted after a brake reline and/or installation using foundation or brake geometry problems. the following procedure: 16 ½ x 7” 71.5 24.13 8.9 8.9 1. Position a wrench or socket over the adjusting 16 ½ x 7” 77.5 17.52 28.1 28.1 mechanism. When the manual brake ad- 16 ½ x 7” 77.5 20.63 21.9 21.9 ! CAUTION : 16 ½ x 7” 77.5 21.38 20.4 20.4 juster brake adjustment is completed, the NOTE: If the self-adjusting brake adjuster is adjusting hex should be positioned so the 16 ½ x 7” 77.5 23.75 15.7 15.7 equipped with a pawl, remove the pawl for the locking sleeve engages it, thus locking it in brake adjustment and then properly reinstall 16 ½ x 7” 77.5 24.13 14.9 14.9 place. If the locking sleeve does not engage the pawl (see Fig. 2, Style C) . Tighten the 16 ½ x 8 5/8” 71.5 17.52 22.1 22.1 the adjusting hex, the brake adjuster can back pawl to 15 - 20 ft.-lbs. 16 ½ x 8 5/8” 71.5 20.63 15.9 15.9 itself off. 16 ½ x 8 5/8” 71.5 21.38 14.4 14.4 2. Brake adjuster with lock screw ball Indent 2. Rotate the adjusting mechanism until the brake 16 ½ x 8 5/8” 71.5 23.75 9.7 9.7 type lock mechanism—Back off (turn coun- shoes contact the drum. Pull on the brake terclockwise) the worm shaft lock screw (if 16 ½ x 8 5/8” 71.5 24.13 8.9 8.9 adjuster by hand to make sure it will not move. applicable). Make the necessary adjustment If there is movement, adjustment was made in 16 ½ x 8 5/8” 77.5 17.52 28.1 28.1 by turning the adjusting hex as described in the wrong direction and the adjusting hex 16 ½ x 8 5/8” 77.5 20.63 21.9 21.9 item number 1 of this section. Following brake must be turned in the opposite direction until 16 ½ x 8 5/8” 77.5 21.38 20.4 20.4 adjustment, make certain that the lock ball or it will go no further. 16 ½ x 8 5/8” 77.5 23.75 15.7 15.7 plunger engages the worm shaft indent. With- 3. Reverse the rotation, backing the brake ad- 16 ½ x 8 5/8” 77.5 24.13 14.9 14.9 out such engagement, the slack adjuster can juster off one-half (1/2) turn. back itself off. Notes: 16.5 x 8 5/8” is a centerline brake -same spider position as 16.5 x 7” 4. Measure the chamber power stroke at 90-100 Type 2424 = 7.5” O.D. psi brake application pressure as described in Type 3030 = 8.31” O.D. B. Self-Adjusting Brake Adjuster the previous section. Brake Adjustment Procedure— 5. Take a free stroke measurement as outlined A self-adjusting brake adjuster should not have to be in the section entitled FAILURE ANALYSIS. manually adjusted except for initial installation and at Make sure you have at least 3/8" free stroke. brake reline. Instead of manually adjusting the slack, Free stroke of less than 3/8" can cause brake perform the following procedure during inspection: drag. If you cannot maintain the maximum legal stroke and the free stroke is less than 3/ Chamber Power Stroke: A power stroke at 90-100 8", contact the brake manufacturer for foun- psi brake application pressure will check both adjust- dation or brake geometry problems. ment and foundation brake condition. Perform the following:

28 17

NOTE: The brake chamber push rod may the adjusting hex until it will go no further require shortening or replacement to obtain indicating that either the shoes have con- Axle Options the proper installation length. tacted the drum or the adjusting hex has been turned in the wrong direction. Pull on the brake 8B. Make sure the control arm is bottomed out in adjuster to make sure it will not move. If there the direction of the arrow or if the control arm is movement, adjustment was made in the has a pointer, align with the cut-out gap pro- wrong direction and the adjusting hex must be ABS Sensors Installed: Slack Adjusters: vided (see Fig. 2, Style D) and then secure all turned in the opposite direction until it will go • Wabco • Haldex anchor bracket hardware. no further. After establishing solid shoe-to- • Haldex 9. Tighten the jam nut. drum contact, back off the adjusting hex 1/4 • Bendix • Bendix 10. After installation, make a brake application turn for worn linings and 1/2 turn when relining • Watson & Chalin - BTC to make certain there is no interference be- brakes. The actuator stroke should be as • Other tween the axle and the suspension compo- short as possible without the brakes dragging. nents in both fully applied and fully released Measure the chamber power stroke at 90-100 positions. Check to ensure that the brake psi as described in subsection “B,” “Self-Ad- Bearings: Seals: adjusters rotate freely and without binding. justing Brake Adjuster Brake Adjustment Pro- 11. Adjust the brakes following the procedure in cedure,” below. Take a free stroke measure- • Watson & Chalin standard • Watson & Chalin standard • Timken the section entitled BRAKE ADJUSTMENT ment as outlined in the section entitled FAIL- • SKF C/R PROCEDURE, below. URE ANALYSIS. Ensure there is at least 3/8" • Stemco • Stemco • Others BRAKE ADJUSTMENT PROCEDURE • Others A

NOTE: All adjustments should be made with cold Hub Cap: brake drums and the brakes fully released. Dust Shield • Watson & Chalin Standard • 16.5” : To avoid possible injury, proper precau- • Stemco • 12.25” tions must be taken to prevent automatic actuation of • Others the brake chambers while adjusting brake adjusters. Always block the wheels or mechanically secure the vehicle. Spring brakes must be mechanically caged or released with air. All brakes should be released. Air Chambers and Spring Brakes Measure this • Watson & Chalin – BTC distance with A. ManualBrake Adjuster • Others chamber "at rest" Brake Adjustment Procedure— Dimension "A" 1. Brake adjusters with locking collar (positive lock type)—Jack up the vehicle. Thor- Fig. 3 10 spline camshafts: (28 spline oughly clean the adjusting hex and locking standard) sleeve area. Position a wrench or socket over the adjusting hex and disengage the locking B Camshaft Enclosures sleeve by depressing it. With the locking sleeve fully depressed, adjust the brakes while rotating the tire and wheel. Use the wrench or socket to turn the adjusting hex until the shoes Notes: contact the drum. Then back off the adjusting hex until the tire and wheel turn freely. The • Total axle price varies according to the options. actuator stroke should be as short as possible • “Watson & Chalin Standard” isusually the best priced option. without the brakes dragging. • New options can be added upon request when quantities/price/availability are suitable. If the vehicle cannot be jacked up, thoroughly Measure this clean the adjusting hex and locking sleeve distance at 90-100 psi at the area. Position a wrench or socket over the brake reservoir gauge. adjusting hex and disengage the locking sleeve Dimension "B" by depressing it. With the locking sleeve fully depressed, use the wrench or socket to turn Fig. 4

18 27

WCN Axle 12.25" Brake Part Number X-Reference

WCN Spindle: Threads 2 5/8"-16 UNS 2A Fuwa FN Hendrickson HN Meritor TN, TQ Spicer (Dana) D22, K22 IMT F22

Bearings: HM212049 Outer HM218248 Inner

Brake shoes: 12 1/4" X 7 1/2" 0.715: Standard FMSI 4692 Fuwa DA Meritor Q Spicer Fast Change IMT TIME

Fig. 2: Self-Adjusting Brake Adjuster Types Camshafts: Standard Lining: GP Std 1 1/2" Cam Bushing, 28 splines Manufacturer Fuwa IMT Meritor Euclid 20 3/4" Left C11-0401-527L 202129-206-LH R607247 E-9753 C. Self-Adjusting Brake Adjuster Removal— D. Self-Adjusting Brake Adjuster Installation— 20 3/4" Right C11-0401-527R 202129-206-RH R607248 E-9754 1. Remove the clevis and link pins and the an- 1. Ensure that the brake chamber is installed in 21 1/8" Left C11-0401-537L N/A N/A N/A chor bracket nut or pawl, if necessary (see the bracket holes appropriate for the self- 21 1/8" Right C11-0401-537R N/A N/A N/A Fig. 2). adjusting brake adjuster arm length. 23 3/8" Left C11-0401-595L 202129-233-LH R607253 E-9759 a.Style A—Remove the clevis and link pins. 2. Clean the camshaft splines. 23 3/8" Right C11-0401-595R 202129-233-RH R607254 E-9760 b.Style B—Remove the retaining ring quick 3. Coat the camshaft splines and the end of the 23 3/4" Left C11-0401-603L N/A N/A E-10925 connect yoke. brake chamber push rod with an anti-seize 23 3/4" Right C11-0401-603R N/A N/A E-10926 c.Style C—Remove the pawl, clevis, and type product. Repair Kit: N/A 2028 R615014 E-2469 link pins. 4. Install either a quick connect nut or threaded d.Style D—Remove the clevis pin and clevis on the brake chamber push rod per the Fuwa / NEW Fuwa / OLD IMT Meritor Euclid anchor bracket nuts. manufacturer’s recommendations. Some Spider Bushing C13-0201 3305-0038 405129 N/A E-759/807 manufacturers offer both quick connect and Spider Seal C14-0201 3957-0038 408101 1205M1105 E-1416 2. Remove the retaining mechanism from the threaded clevises. Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD end of the brake cam shaft. 5. Install the self-adjusting brake adjuster on the 3. Rotate the adjusting mechanism to back the camshaft. Hub Seals Stemco C/R Out-Runner Timken self-adjusting brake adjuster out of the clevis, 6. Install the self-adjusting brake adjuster retain- 6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST if necessary. ing mechanism on the end of the brake cam 315-1504 ring 46305 Classic NLGI#2 Grease 4. Remove the self-adjusting brake adjuster from shaft, being sure to shim it to less than 0.060 the spline end of the brake cam shaft. inch of end play. Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD 7A. Rotate the adjusting mechanism to either NOTE: If a manual brake adjuster is being install a clevis and link pin or to connect the Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard. removed to be replaced with a self-adjusting clevis with a quick connect nut (see Fig. 2, 2- Above supplied for information only. Please measure parts before installing. brake adjuster, the manual or threaded clevis Styles A, B, and C). 3- N/A = Not available must be removed from the brake chamber 7B. For Style D, install the anchor bracket loosely Options: Many options are available - Consult Watson & Chalin Customer Service. push rod (with Style D self-adjusting brake and then rotate the adjusting mechanism to adjuster, the existing clevis is used and addi- install the clevis pin. tional anchor bracket hardware is required). 8A. Using the correct gauge or template, (see Leave the jam nut on the push rod. Fig. 2, Styles A, B, and C) check for the proper mounting angle. Adjust the clevis for the correct angle, if necessary.

26 19

MANUAL BRAKE ADJUSTERS • Type, width, number, and diameter of splines. WCN Axle Manual brake adjusters contain four basic compo- • Clevis pin diameter (do not drive out bushing 16.5" Brake Part Number X-Reference nents: the body, worm gear, worm shaft, and locking to accommodate a larger clevis pin). screw or collar. See Fig. 1. • Brake chamber push rod size (5/8" or 1/2"). • If offset configuration, determine the offset The worm shaft of a brake adjuster incorporates an dimension (right or left side). WCN Spindle: Threads 2 5/8"-16 UNS 2A external adjusting hex. Turning the adjusting hex Fuwa FN rotates the worm shaft which turns the worm gear Hendrickson HN BRAKE ADJUSTER REMOVAL AND Meritor TN, TQ and brake cam shaft, thus spreading the brake shoes INSTALLATION Spicer (Dana) D22, K22 and reducing drum-to-lining clearance. IMT F22 : To avoid possible injury, proper precau- Bearings: HM212049 Outer Light to medium gross axle weight rating (GAWR) tions must be taken to prevent automatic actuation of HM218248 Inner vehicles utilize either a spring-loaded locking sleeve the brake chambers while removing or installing or a lock ball indent adjustment lock to prevent the slack adjusters. Always block the wheels or me- Brake shoes: 16 1/2" X 7" 0.75: Standard 0.88" Thick worm shaft from backing off. chanically secure the vehicle. Spring brakes must be FMSI 4515E 4707 mechanically caged. All brakes should be released. Fuwa GP GP+ Higher torque-rated brake adjusters use the lock ball Meritor Q Q+ or plunger and worm shaft indent principle adjust- A. Manual Brake Adjuster Removal— Spicer Fast Change XL ment lock. The lock ball or plunger must engage the 1. Remove the brake chamber push rod clevis IMT TIME SL worm shaft indent after the adjustment is completed. pin. An audible metallic click can be heard when engage- 2. Remove the retaining mechanism from the Camshafts: GP & GP+, 1 5/8" Cam Head Journal, 28 Spline ment is made. end of the brake camshaft. Manufacturer Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid 3. Rotate the adjusting hex to back the brake 17 1/2" Left C11-0301-445L N/A M16WKL25-175 R607227 E-9731 SELF ADJUSTING BRAKE ADJUSTERS adjuster out of the clevis. 17 1/2" Right C11-0301-445R N/A M16WKR25-175 R607228 E-9732 While self-adjusting brake adjuster designs vary in 4. Remove the brake adjuster from the spline 20 5/8" Left C11-0301-524-L 3304-0621L M16WKL25-205 R607229 E9733 the manner in which they are installed and operate, end of the brake cam shaft. 20 5/8" Right C11-0301-524R 3304-0621R M16WKR25-205 R607230 E9734 all are designed to automatically maintain a prede- 21 3/8" Left C11-0301-543-L N/A M16WKL25-213 N/A N/A termined drum-to-lining clearance or brake chamber B. Manual Brake Adjuster Installation— 21 3/8" Right C11-0301-543R N/A M16WKR25-213 N/A N/A stroke. Some self-adjusting brake adjusters adjust 1. Install the brake adjuster on the cam shaft so 23 3/4" Left C11-0301-604-L N/A M16WKL25-236 R607231 E-9735 upon the brake application stroke, others adjust the adjustment hex and grease fitting (if so 23 3/4" Right C11-0301-604R N/A M16WKR25-236 R607232 E-9736 upon release. Self-adjusting brake adjusters should equipped) are accessible for servicing. 24 1/8" Left C11-0301-613-L 3304-0622L M16WKL25-242 R607277 E-10909 not have to be manually adjusted while in service. 2. Align the brake adjuster arm with center of the 24 1/8" Right C11-0301-613-R 3304-0622R M16WKR25-242 R607278 E-10910 However, manual adjustments can be made tempo- push rod clevis. Install the clevis pin and Repair Kit: N/A N/A 8132803 R615019 E-9790A rarily to get a vehicle to a maintenance facility for secure it with a new cotter pin. inspection and repair, if necessary. Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid 3. Check to be sure the angle formed by the brake adjuster arm and the brake chamber Spider Bushing C13-0302 3306-0011 M16HD106 R627034 E-9789 Self-adjusting brake adjusters do not push rod is greater than 90° when the brake Spider Seal C14-0300 3307-0011 M16HH103 R627015 E-3991 ! CAUTION adjuster is in the released position. Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD eliminate or reduce the need for periodic inspection 4. Install the brake adjuster retaining mecha- and maintenance of the adjuster components and nism on the end of the brake cam shaft, being Hub Seals Stemco C/R Out-Runner Timken attaching hardware. Self-adjusting brake adjusters 6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST should never be operated as a manual adjuster, if the sure to shim it to less than 0.060 inch of end 315-1504 ring 46305 Classic NLGI#2 Grease self-adjusting function is not operating properly. play. 5. Tighten the jam nut on the push-rod-to-clevis

attachment (1/2 - 20 300-400 in. Ibs. 5/8 - 18 Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD BRAKE ADJUSTER REPLACEMENT When replacing a brake adjuster, it is recommended 400 in. Ibs.). Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard. that the replacement be of the same size as the 6. After installation, make certain there is ad- 2- Above supplied for information only. Please measure parts before installing. original equipment. All self-adjusting brake adjusters equate clearance in both the fully applied and 3- N/A = Not available on a vehicle should be made by the same manufac- fully released positions. Check to ensure that Options: Many options are available - Consult Watson & Chalin Customer Service. turer. To identify the proper replacement, the follow- all brake adjusters rotate freely and without ing slack adjuster key dimensional checks are rec- binding. ommended. 7. Adjust the brakes by following the procedure • Arm length (center of spline to center of arm in the section entitled BRAKE ADJUSTMENT hole to be used). PROCEDURE.

20 25

Recommended Practice WCP Axle 16.5" Brake Part Number X-Reference RP 609B VMRS 013-001, 013-002 WCP Spindle: Threads 3.48"-12 UN-2A Fuwa FP SELF-ADJUSTING AND MANUAL BRAKE ADJUSTER Hendrickson HP Meritor TP REMOVAL, INSTALLATION AND MAINTENANCE Spicer (Dana) P22 IMT F24

PREFACE with a clevis and the spline end is installed on the Bearings: HM518445 Outer The following Recommended Practice is subject to brake camshaft. Primarily, the brake adjuster is a HM518445 Inner the Disclaimer at the front of TMC’s Recommended lever that converts the linear force of the air chamber Maintenance Practices Manual. Users are urged to push rod into a torque which turns the brake cam- Brake shoes: 16 1/2" X 7" Standard Thick read the Disclaimer before considering adoption of shaft and applies the brakes. FMSI 4515 4707 any portion of this Recommended Practice. Fuwa GP GP+ Two types of brake adjusters are in use: manual type Meritor Q Q+ PURPOSE AND SCOPE brake adjusters, which periodically require a manual Spicer Fast Change XL The purpose of this Recommended Practice (RP) is adjustment; and self-adjusting brake adjusters, which IMT TIME SL to provide information regarding the removal, instal- automatically adjust during normal service braking lation, operation, maintenance, and selection of applications. All brake adjusters use the worm and Camshafts: GP & GP+, 1 5/8" Cam Head Journal, 28 Spline heavy-duty vehicle manual and self-adjusting brake gear principle and fundamentally differ only in their Manufacturer Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid adjusters. torque limit specification. 17 1/2" Left C11-0301-445L N/A M16WKL25-175 R607227 E-9731 17 1/2" Right C11-0301-445R N/A M16WKR25-175 R607228 E-9732 INTRODUCTION NOTE: Manual and self-adjusting brake adjusters 20 5/8" Left C11-0301-524-L 3304-0621L M16WKL25-205 R607229 E9733 In an S-cam type foundation brake, the final link are for brake adjustment and will not compensate for 20 5/8" Right C11-0301-524R 3304-0621R M16WKR25-205 R607230 E9734 between the pneumatic system and the foundation normal wear characteristics and maintenance re- 21 3/8" Left C11-0301-543-L N/A M16WKL25-213 N/A N/A 21 3/8" Right C11-0301-543R N/A M16WKR25-213 N/A N/A brake is the brake adjuster. The arm of the brake quirements associated with foundation brakes. 23 3/4" Left C11-0301-604-L N/A M16WKL25-236 R607231 E-9735 adjuster is fastened to the push rod of the chamber 23 3/4" Right C11-0301-604R N/A M16WKR25-236 R607232 E-9736 24 1/8" Left C11-0301-613-L 3304-0622L M16WKL25-242 R607277 E-10909 BALL INDENT TYPE SLACK ADJUSTER POSITIVE LOCK TYPE SLACK ADJUSTER 24 1/8" Right C11-0301-613-R 3304-0622R M16WKR25-242 R607278 E-10910 Repair Kit: N/A N/A 8132803 R615019 E-9790A

Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid BODY Spider Bushing C13-0302 3306-0011 M16HD106 R627034 E-9789 LOCK SCREW Spider Seal C14-0300 3307-0011 M16HH103 R627015 E-3991 Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD LOCKING COLLAR Hub Seals Stemco C/R Out-Runner Timken 6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST WORM 315-1504 ring 46305 Classic NLGI#2 Grease SHAFT ADJUSTING ADJUSTING Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD HEX HEX Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard. WORM 2- Above supplied for information only. Please measure parts before installing. GEAR 3- N/A = Not available Options: Many options are available - Consult Watson & Chalin Customer Service.

Fig. 1: Manual Brake Adjusters

24 21

AXLE LUBRICATION

Oil and grease suggested change intervals:

Varying loads and driving conditions will affect the service interval requirements. This chart is a generally accepted guide. Always work in a clean area and clean all parts with proper solvents before use. Never refill the hub with used oil. Contaminated lubricants can quickly destroy the entire assembly.

TIME or DISTANCE OIL GREASE BRAKES COMPONENTS 1,000 miles 1,600 km Check the oil level and replace the oil if it is contaminated. Check for leaks. Replace oil and FASTENER TORQUE SPECIFICATIONS seal if hub has been removed. See the "Add" and "Full" rings on the hub cap Description Thread Grade Torque 12,000 miles 19,200 km Check brake adjustment Cam bracket bolts: 3/8” 5 40 ft-lbs, 55Nm 30,000 miles 48,00 km or Heavy Duty Use (On/Off Road) Heavy Duty Use Check wear in the linings, 10mm 8.8 40 ft-lbs, 55Nm six months Change the oil (On/Off the cams, and the spider Road) Grease the bushings. Grease the Hub Cap 5/16”-18UNC 5 15 ft-lbs, 28Nm bearings brake actuating 100,00 miles 160,000km Normal Use Normal Use or every year Change the oil Grease the bearings Dust Shield 5/16” – 18UNC 5 15 ft-lbs, 28Nm Varies Consult the semi-fluid synthetic grease Manufactrurer for recommendations. Also replace this grease if the hub is removed. Air Chambers Type 9, 12, 16 7/16”- 14UNC N/A 30-40 ft-lbs, 40-55Nm Type 20, 24, 30 5/8”- 11UNC N/A 100-115 ft-lbs, 135-155Nm CAUTION: Do not mix lubricants types.

Lubricants: Spindle nuts; see “Wheel Bearing Adjustment Procedures” TMC RP618

The following GREASE properties are recommended Soap type - Lithium Complex or Equivalent Dropping point - 446ºF (230ºC) Minimum Consistency - NLGI No. 2 or No.1 Additives - Corrosion & Oxidation Inhibitors, EP optional Base Oil - Solvent Refined Petroleum oil

The following Oil properties are recommended

Gear Oil API GL-5 Performance level

SAE 90 Normal Duty SAE 75W, SAE 80W Extreme cold environment SAE 140 Extreme hot environment

22 23

AXLE LUBRICATION

Oil and grease suggested change intervals:

Lubricants: Spindle nuts; see “Wheel Bearing Adjustment Procedures” TMC RP618

The following Oil properties are recommended

Gear Oil API GL-5 Performance level

SAE 90 Normal Duty SAE 75W, SAE 80W Extreme cold environment SAE 140 Extreme hot environment

22 23

Fig. 1: Manual Brake Adjusters

24 21

20 25

WCN Axle 12.25" Brake Part Number X-Reference

WCN Spindle: Threads 2 5/8"-16 UNS 2A Fuwa FN Hendrickson HN Meritor TN, TQ Spicer (Dana) D22, K22 IMT F22

Bearings: HM212049 Outer HM218248 Inner

Brake shoes: 12 1/4" X 7 1/2" 0.715: Standard FMSI 4692 Fuwa DA Meritor Q Spicer Fast Change IMT TIME

must be removed from the brake chamber 7B. For Style D, install the anchor bracket loosely Options: Many options are available - Consult Watson & Chalin Customer Service. push rod (with Style D self-adjusting brake and then rotate the adjusting mechanism to adjuster, the existing clevis is used and addi- install the clevis pin. tional anchor bracket hardware is required). 8A. Using the correct gauge or template, (see Leave the jam nut on the push rod. Fig. 2, Styles A, B, and C) check for the proper mounting angle. Adjust the clevis for the correct angle, if necessary.

26 19

18 27

foundation or brake geometry problems. the following procedure: 16 ½ x 7” 71.5 24.13 8.9 8.9 1. Position a wrench or socket over the adjusting 16 ½ x 7” 77.5 17.52 28.1 28.1 mechanism. When the manual brake ad- 16 ½ x 7” 77.5 20.63 21.9 21.9 ! CAUTION : 16 ½ x 7” 77.5 21.38 20.4 20.4 juster brake adjustment is completed, the NOTE: If the self-adjusting brake adjuster is adjusting hex should be positioned so the 16 ½ x 7” 77.5 23.75 15.7 15.7 equipped with a pawl, remove the pawl for the locking sleeve engages it, thus locking it in brake adjustment and then properly reinstall 16 ½ x 7” 77.5 24.13 14.9 14.9 place. If the locking sleeve does not engage the pawl (see Fig. 2, Style C) . Tighten the 16 ½ x 8 5/8” 71.5 17.52 22.1 22.1 the adjusting hex, the brake adjuster can back pawl to 15 - 20 ft.-lbs. 16 ½ x 8 5/8” 71.5 20.63 15.9 15.9 itself off. 16 ½ x 8 5/8” 71.5 21.38 14.4 14.4 2. Brake adjuster with lock screw ball Indent 2. Rotate the adjusting mechanism until the brake 16 ½ x 8 5/8” 71.5 23.75 9.7 9.7 type lock mechanism—Back off (turn coun- shoes contact the drum. Pull on the brake terclockwise) the worm shaft lock screw (if 16 ½ x 8 5/8” 71.5 24.13 8.9 8.9 adjuster by hand to make sure it will not move. applicable). Make the necessary adjustment If there is movement, adjustment was made in 16 ½ x 8 5/8” 77.5 17.52 28.1 28.1 by turning the adjusting hex as described in the wrong direction and the adjusting hex 16 ½ x 8 5/8” 77.5 20.63 21.9 21.9

item number 1 of this section. Following brake must be turned in the opposite direction until 16 ½ x 8 5/8” 77.5 21.38 20.4 20.4 adjustment, make certain that the lock ball or it will go no further. 16 ½ x 8 5/8” 77.5 23.75 15.7 15.7 plunger engages the worm shaft indent. With- 3. Reverse the rotation, backing the brake ad- 16 ½ x 8 5/8” 77.5 24.13 14.9 14.9 out such engagement, the slack adjuster can juster off one-half (1/2) turn. back itself off. Notes: 16.5 x 8 5/8” is a centerline brake -same spider position as 16.5 x 7” 4. Measure the chamber power stroke at 90-100 Type 2424 = 7.5” O.D. psi brake application pressure as described in Type 3030 = 8.31” O.D. B. Self-Adjusting Brake Adjuster the previous section. Brake Adjustment Procedure— 5. Take a free stroke measurement as outlined A self-adjusting brake adjuster should not have to be in the section entitled FAILURE ANALYSIS. manually adjusted except for initial installation and at Make sure you have at least 3/8" free stroke. brake reline. Instead of manually adjusting the slack, Free stroke of less than 3/8" can cause brake perform the following procedure during inspection: drag. If you cannot maintain the maximum legal stroke and the free stroke is less than 3/ Chamber Power Stroke: A power stroke at 90-100 8", contact the brake manufacturer for foun- psi brake application pressure will check both adjust- dation or brake geometry problems. ment and foundation brake condition. Perform the following:

28 17

Notes: 1- N/R = Not required for this certification 2- Metric tonnes. 3- 16.5 x 7 is Q+ REV. 2 - 09.28.2009

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road, t and adjuster. he bar,

indicat- and a

adjust- adjust-

a spring

sure

or with in with brake brake brak back- when If RP 609B—6 clear pawl then

is per- pull

the the the the the the

re- by as at e a a a it Fig. 5 29 Manual FAILURE slack wear. To adjusters that push curs (see the clevis on (see While problem are: marking marked NOTE: Brake do the brake ANALYSIS There it Fig. rod this, attachment the incorporates brake Some

Adjuster

to system

with

5, near should Fig. 5, chamber marking Lever back warn is diagram the chamber a brake its Fig. 6 mark has off

of diagram C). foundation Failure be clevis end

B themselves

an wherever the

two B). a chamber inspected on which

over-stroke stroke push adjusting attachment There basic the Analysis

Measure Dimension using lever brake

brake. is

rod brake over-stroke

features.

push alert also exposed may

for

opposite hex "applied —Manual condition. is chamber gear vary, indicator to rods

until with a signal

mark

"B" They from are oc- the set

all its

30 15

Recommended Practice

RP 618 VMRS 018

WHEEL BEARING ADJUSTMENT PROCEDURES

14 31

Tire Inflation Spindle preparation for PSI, Tiremax and Airgo is standard.

Cam position Ahead of axle Behind the axle

Cam Length See specific model drawing

Fig. 1: Dial Indicator Set-Up

32 13

42.5 20.75 20,220 23500 assistance. assistance. 41.5 21.25 19,740 23000

12 33

TABLE 1

WHEEL BEARING ADJUSTMENT PROCEDURE

12 2-5/8" 300-400 lb•ft Trailer 1/4 Turn (66.7 mm) (407-542 N•m) and over 16

34 11

Recommended Practice

Model: WCP RP 631A VMRS 018

Bearing Group: Inner: HM518445, Outer: HM518445 RECOMMENDATIONS FOR WHEEL END LUBRICATION

10 35

Fleet managers should also reference original equipment manufacturer (OEM) maintenance and service manuals as appropriate.

A. Non-Driven Oil-Lubricated Wheel Ends

36 9

: If grease packing is done by hand, appropriate protection — such as gloves and cloth- WCN6D ing — should be worn to minimize skin contact with the grease. 6” DROP CENTER AXLE BEARINGS: HM218248 + HM212049 Mandatory Grease Area WATSON & CHALIN CAPACITY Air Ride SUSPENSION ! CAUTION : Overfilling or under filling a wheel hub RATING for AIR RIDE SUSPENSIONS TUBE WALL with lubricant may result in premature component failure. THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY) 0.58” 0.75 MOMEN Hub Fill Procedures: Semi-fluid Grease SPRING T ARM AXLE BEAM AXLE BEAM If tires are not mounted, install the hub on the spindle. SPINDLE TRACK SEATS (INCHE CAPACITY CAPACITY Fig. 4: Packing of Bearing Cone Take care to not damage the seal. Use lifting equip- TYPE (INCHES) (INCHES) S) GAWR. (lbs.) GAWR. (lbs.) ment to align the hub assembly with the spindle WCN 71.5 38 16.75 22,500 25,000 gasket, and all questionable parts. For detailed pro- taking care to not damage the seal and spindle cedures, refer to TMC RP 622. WCN 71.5 37 17.25 21,850 24,320 threads and push the hub assembly into position. WCN 71.5 36 17.75 21,230 23,640 NOTE: If retrofitting an oil or grease system with a WCN 71.5 35 18.25 20,650 22,990 With the hub supported, before installing the outer semi-fluid grease, be sure to note the need for WCN 71.5 34 18.75 20,100 22,380 bearing cone, begin filling from the bottom of the hub special cleaning instructions, fill procedures and cavity. Top-off by placing the pump nozzle above the WCN 71.5 33 19.25 19,580 21,800 equipment (i.e., vented hubcap). spindle, and continue pumping grease into the hub WCN 71.5 32 19.75 19,080 21,240 cavity. (See Figure 5.) WCN 71.5 31 20.25 18,610 20,720 Component Lubrication WCN 71.5 30 20.75 18,160 20,220 Pack the inner and outer wheel bearing cones full with grease. Work the grease into the bearing in the WCN 71.5 29 21.25 17,730 19,740 direction of the arrow shown in Figure 4 by machine

Apply Grease Around Adjusting Nut

Fig 5A: Lubrication Fill Fig. 5: Semi-Fluid Grease Top Off Procedure Semi-Fluid Grease (No. 00)

8 37 Maintenance Manual. Verify end play (0.001" to 0.005") with a dial indicator. Before installing the hubcap, apply a coating of grease around the wheel bearing adjustment nut(s).

Hubcap Considerations: Semi-fluid Grease Use an appropriate tamper-proof, vented hubcap. These hubcaps prevent gear oils from being acci-

dentally added to grease-filled wheel ends.

NOTE: Because of the hubcap’s special venting capability and the properties of the semi-fluid grease, do not fill the hubcap with grease.

Fig. 6: Lubrication Fill Greases (Nos. 1,2, & 3)

38 7

temporarily ings 0.005") and thenfillthehubcavity. of and Use Hubcap Considerations:HardGrease grease aroundtheadjustingnut(s). being hubcaps damage. clean While assembly intoposition. damage hub Install Hub FillProcedures:Oil hub 618 andRP622. ers, If Inspection andPreparation axle the recommendation due. tionable axles NOTE: CONSIDERATIONS DRIVEN AXLELUBRICANTWHEELEND special carenottocovertheventwithgrease. coat NOTE: the hubcapshouldbeventedornon-vented. Pre-lubricate Component RP the cones ©2003—TMC/ATA ! ! the lubricant CAUTION CAUTION 622. axle wheel maintain cavity shafts, removing assembly the Replace an with

wheel

are oil added the the with

with appropriate

reservoir. parts. interior the and

For prevent a wheel oil

hub with grease end this

metal clean and

restrict hub end

seal

lubricated.

to push proper additional Lubrication

: : a seal,

the

In Failure all is For oil. with grease-filled Recommended components may

seals, dial and surfaces is

oil and lubricant hub supported, of

gear contaminants into disassembled, inner Use before axle or detail

bath the

lubrication the contribute bearing indicator. tamper-proof, spindle cap

prevent as to position

oils lifting information

seal flange spindle systems,

and lubricate documented procedures, with

is of installation. from

used, wheel supplier cups,

including fill the equipment threads. outer

the

gasket,

may

to or Apply

Practice, the film and taking same being

wheel clean

push proper do

bearing it axle,

ends. refer result hubcap. hub is of

wheel to not lubricant

in Push

refer a necessary and

all grease. type

into

accidentally Grease determine and seal

care and RP to to

cavity pack coating Follow circulation in all bearings,

correctly TMC align all position 622. bearing bearing to the

used inspect fasten- failure. These driven to ques-

bear- TMC resi- RP with Use hub

not will the the RP

Fill

to of in

if 631A—5 39 bearings that top f Install be and manuf lubricated Oil NOTE: 622 andRP618.) is is achieve Install 0.005") withadialindicator. Maintenance Adjust to units The REQUIREMENTS MAINTENANCE debris. Recheck or The axle reservoir. sembly These for inspectionandservicerecommendations. ings. gasket ous Walk Level INSPECTION A. OILLUBRICATEDWHEELENDS fill seepage linings arenoted. Take priate action. lange ! operating always pre-set move level. raised is off CAUTION would inspection signs following through supplied whose Check around appropriate a 1—Simple the the the recommendations wheel and cturer’s Always of

final gaske

the

is the with wheel outer

to a the

with lubricant flanged give of reason

minimum

wheel properly vocation for the

fill lubricant vehicle

main :

bearings

system, the directly Manual. grease lubricant CRITERIA

oil inspection s bearing, level, Do the t. check criteria broken

ends, pecif bottom

AND Inspection from action

T axle

seal sump drive appearance

for not level, orque

and

icat

and each is

of to refer the when further into

including

the are or INSPECTION

per strictly Verify

areas, pack of washers tube the eight leakage, ion. if axle check for

completely if missing axle depend leaks criteria end the axle the not to required. TMC’s

wheel f

the Clean-up the lange

systems inspection (Pre-Trip/In-Service) shaft during inches the fill on-highway breather end of oil intended opposite

differential. wheel-ends

of the proper or wheel

and the

plug

soaked components. drive on a ends such are RP oil with play proper leaking

drive nuts The for free adjusting the operation.

soaked any manufacturer or

618 intended

ends oil

axle one a for wheel as and hole (0.001" proper

oil of

assembly o axle brake

be new level

use lubricant (See

v t

for or unitized system. o dirt hubcap fill er minute appro- will

sure

wheel brake in

OEM spills nuts. must obvi- only. a level end.

axle

Any and and

x the RP as- lin- for To be l to e it

40 5

Parts X- Reference See “Reference Information” section

4 41 ng er i -XXX

Num b h

id t

71.5” 120 ” 73.0” 77.5” 95.5” 715 ck

r a T 715 120 730 775 955

Drop Drop

t ype

ST Axle Inverted Drop Inverted Drop

9” Straight 9” 6” 6”

I I 9 6

9D 6D

7.5 7 Size x

x 4 7 67 x x

Brake

16.5 12.25

15 18

67 27

54 87

ents 0.5 Solid 10mm

0.58 0.75

kness

5 incre m LE Th i

RS A X 4 3 5 6 1/8 S E Wall B By

NU M SAMPLE

r o type Axle Part Numbering Guide r Spindle type

Spindle

Prop a

A45 N D22

FF A26/K30 Spindle

01 04 03 02 Spindle

F P K A N* 75- 0 20- 0 15- 0 15- 0

on & Chalin 67ST 7 27ST 1 67ST 7 67ST 7 x s f i t

a WC Pr e WCN 1

WCP 1 WCN 1 WCP 1

42 3 G. : 4/28/2009 8:36 AM O AXLE N