PARTS CATALOG & MAINTENANCE MANUAL TANDEM AXLE COMBO PS2-SC1248U / PS2-SC1401U
2 INTRODUCTION A pre-trip inspection is required each time a commercial motor vehicle goes on the road; this covers important and basic chassis components. This inspection is essential each time a chassis is to be operated. Do not operate a Trend chassis (or any piece of highway equipment) with un-repaired damaged components. According to the chassis maintenance manual, frequent maintenance is required. The engine will be damaged if neglected. It will harm the engine over time and result in greater wear than usual. Additionally, improper car care can have detrimental consequences on the environment, such as pollution, so the provided car maintenance handbook must be followed. Honda established a check plan for automobiles that requires all models to be evaluated every six months or every 10,000 kilometers, whichever comes first. OPERATE WITHIN THE RULES Trend chassis are designed to operate at legal highway speeds, on improved, paved roads, with the maximum GVWR shown on the VIN tag. GVWR and GAWR are not to be exceeded. Always operate within local weight and speed regulations. SYSTEMATIC INSPECTIONS A successful chassis maintenance and repair program starts with a highquality chassis review, which is a crucial component. Always begin with the right checks to determine whether a chassis can run safely. Until the total state of the chassis is adequately evaluated, there can be no effective maintenance and repair program. Equipment dependability and durability depend on thorough verification, as detailed in this article. The most common systematic chassis inspection is to start at the front bolster, move to the road side, the rear bolster and finally the curb side. You’re looking for what is located in each of those four main areas, e.g. lights / wiring / locks / keepers / gladhands / hoses / 7-way in the front bolster area; similar as you move along each of the other areas. Another approach is to follow the main chassis components: structural frame / landing gear / securing devices / slider frames / electrical / air / suspension / brakes / wheels & tires, etc. This approach probably requires moving around the chassis a bit more but certainly has its advantages in being complete. Most major chassis component suppliers have their own maintenance recommendations which they post on-line. We have attached a few files here for the convenience of our lessees
3 Contents INTRODUCTION…………………………………………………………………………………………………. 2 GENERAL DIMENSIONS…………………………………………………………………………………. 4 MAINTENANCE SCHEDULE …………………………………………………………………………. 6 MAIN FRAME ……………………………………………………………………………………………………… 7 KINGPIN & UPPER COUPLER………………………………………………………………………. 8 SLIDER ASSEMBLY …………………………………………………………………………………………… 9 LOCKING DEVICES …………………………………………………………………………………………… 10 SUSPENSION………………………………………………………………………………………………………. 11 SUSPENSION COMPONENT…………………………..…………………………………………….. 12 SUSPENSION FASTENERS TORQUE………………………………………………………….. 13 AXLES …………………………………………………………………………………………………………………….. 14 AXLES COMPONENT………………………………………………………………………………………… 15 RIM & TIRE ……………………………………………………………………………………………………………. 16 TIRE INFLATION …………………………………..……………………………………………………………. 17 LANDING GEAR …………………………………………………………………………………………………. 19 BRAKE SYSTEM(ABS)…………………….……………………………………..………………………….. 20 BRAKE CHAMBER…………..………………………………………………………………………………… 22 SLACK ADJUSTER……………..………………………………………………………………………………. 23 GLAD HAND…………………………………………………………………………………………………………. 24 ELECTRICAL ………………………………………………………………………………………………………… 25 ELECTRICAL SYSTEM COMPONENT…………………….……………………………………. 26 WARRANTY………………………………………………………………………………………………………….. 27 CONDITION OF THE WARRANTY………………………..………...…………………………… 29 HOW TO PROCESS A WARRANTY COMPLAINT & CLAIM………………… 30
4 GENERAL DIMENSIONS
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6 MAINTENANCE SCHEDULE INITIAL PERIOD EVERY MONTH EVERRY 3 MONTHS EVERRY 6 MONTHS EVERRY 9 MONTHS EVERRY 12 MONTHS AT BRAKE RE-LINE FRAME STRUCTURE ✓ FRAME FASTENERS ✓ FRAME FASTENERS TORQUE ✓ KINGPIN & UPPER COUPLER ✓ LOCKING DEVICES ✓ LANDING GEAR LUBRICATION ✓ LANDING GEAR HARDWARE ✓ SUSPENSION STRUCTURE ✓ SUSPENSION FASTENERS TORQUE ✓ HUB CAP & WHEEL SEALS ✓ BRAKE ADJUSTMENT & RE PACK WHEEL BEARING ✓ BRAKE LINING WEAR ✓ CAMSHAFT COMPONENTS & LUBRICATION ✓ WHEEL END COMPONENTS ✓ BRAKE CHAMBER & SLACK ADJUSTERS ✓ LUG NUTS & HUB CAP NUT ✓ AIR BRAKE SYSTEM ✓ ELECTRICAL SYSTEM ✓
7 MAIN FRAME ASSEMBLY VISUAL INSPECTION BEFORE EACH OPERATION ▪ MISSING COMPONENTS ▪ FASTENERS ▪ CRACKED WELDS ▪ CRACKED METAL ▪ DISTORTED COMPONENTS PERIODIC INSPECTION EVERY THREE MONTHS ▪ LOCKING DEVICES FUNCTIONING PROPERLY ▪ SLIDER LOCK PIN S FUNCTIONING PROPERLY ▪ LARGE AREAS OF MISSING PAINT ▪ ABNORMAL WEAR WARNING DAMAGED PARTS, CRACKED WELDS, OR ABNORMAL WEAR MAY RESULT IN PROPERTY DAMAGE, SERIOUS INJURY, OR DEATH.
8 KINGPIN & UPPER COUPLER ASSEMBLY VISUAL INSPECTION BEFORE EACH OPERATION ▪ CRACKED WELDS ▪ CRACKED METAL ▪ DISTORTED COMPONENTS ▪ ABNORMAL WEAR ▪ NICKS ▪ GOUGES PERIODIC INSPECTION EVERY THREE MONTHS OR 30,000 MILES ▪ USING A KINGPIN GAUGE CHECK THE KINGPIN LENGTH. ▪ USING A KINGPIN GAUGE CHECK THE WEAR ON BOTH THE 2 INCH AND 2.88 INCH DIAMETERS. REPLACE THE KINGPIN IF THE APPROPRIATE DIAMETERS ENTERS THE GAGE SLOT
9 SLIDER INDEX PIN ASSEMBLY VISUAL INSPECTION BEFORE EACH OPERATION ▪ MISSING COMPONENTS ▪ FASTENERS ▪ CRACKED WELDS ▪ CRACKED METAL PERIODIC INSPECTION EVERY THREE MONTHS ▪ DISTORTED COMPONENTS ▪ LARGE AREAS OF MISSING PAINT ▪ ABNORMAL WEAR
10 LOCKING DEVICES VISUAL INSPECTION BEFORE EACH OPERATION ▪ MISSING COMPONENTS ▪ FASTENERS ▪ CRACKED WELDS ▪ CRACK METAL ▪ ENSURE TWIST LOCKS ARE RETAINED IN WORKING POSITION & LOCK PROPERLY PERIODIC INSPECTION ANNUALLY ▪ LUBRICATE TWIST LOCKS & ENSURE SMOOTH OPERATION Middle Twistlock Front Twistlock Pin Lock End Casting
11 SUSPENSION VISUAL INSPECTION BEFORE EACH OPERATION ▪ MISSING COMPONENTS ▪ BUSHINGS WEAR ▪ FASTENERS ▪ CRACKED WELDS ▪ CRACKED METAL ▪ BROKE OR CRACKED LEAF SPRINGS INITIAL BREAK IN PERIOD FIRST 1,000 MILES ▪ ALL FASTENERS SHOULD BE CHECKED TO ENSURE THAT RECOMMENDED TORQUE VALUES ARE BEING MAINTAINED. PERIODIC INSPECTION EVERY FOUR MONTHS OR 25,000 MILES ▪ ALL FASTENERS SHOULD BE CHECKED TO ENSURE THAT RECOMMENDED TORQUE VALUES ARE BEING MAINTAINED.
12 SUSPENSION COMPONENTS
13 SUSPENSION FASTENERS TORQUE
14 AXLES AFTER FIRST 3,000 MILES OR AFTER FIRST MONTH EVERY 10,000 MILES OR EVERY MONTH EVERY 50,000 MILES OR EVERY SIX MONTHS EVERY 100,000 MILES OR EVERY TWELVE MONTHS CHECK BRAKE LININGS FOR WEAR ✓ ✓ CHECK BRAKE LINING TO DRUM CLEARANCE ✓ ✓ CHECK S-CAMSHAFT FOR PROPER OPERATION ✓ ✓ LUBRICATE SCAMSHAFT BEARING BUSHINGS ✓ ✓ CHECK SLACK ADJUSTERS FOR CORRECT FUNCTION ✓ ✓ CHECK AIR BRAKE SYSTEM FOR LEAKS ✓ ✓ CHECK SERVICE & PARKING BRAKE PERFORMANCE ✓ ✓ CHECK AXLE COMPONENTS FOR CRACKS OR DAMAGE ✓ ✓ CHECK HUB LUBRICATION LEVEL OR EXCESSIVE LEAKAGE ✓ ✓ PACK HUB BEARINGS WITH FRESH LUBRICANT ✓ CHECK WHEEL BEARING END PLAY ✓ ✓ CHECK TORQUE OF ALL NUTS & BOLTS ✓ ✓
15 AXLES COMPONENTS
16 RIM & TIRE VISUAL INSPECTION BEFORE EACH OPERATION ▪ SEVERE RUST OR CORROSION ▪ METAL CRACKS ▪ BENT FLANGES ▪ RUST STREAKS BEHIND LUG NUTS ▪ DEEP TOOL MARKS ON RINGS OR IN GUTTER AREAS ▪ LOOSE, MISSING, OR DAMAGED NUTS ▪ PUNCTURES OR BULGES ▪ ABNORMAL TIRE PRESSURE ▪ EXCESSIVE WEAR ▪ DRY ROTTING RUBBER
17 TIRE INFLATION Tire Inflation System Inspection Interval Guidelines Tire inflation system inspection intervals depend on factors such as the environment, mileage, and loading. For example, container chassis service is a light-duty application, because it usually involves an on-highway environment and low mileage. Light-duty applications require extended inspection intervals. Dump trailer service is a heavy-duty application, because it usually involves an offhighway environment and heavy loading. Heavy-duty applications require reduced inspection intervals. Installation of a ThermALERT™ system does not eliminate the need to perform recommended wheel-end maintenance. Inspect the tire inflation system components listed here for correct operation on the following schedule. General Inspect the system wheel-end components whenever you remove a tire. Light-Duty Service Inspect the system every 100,000 miles or 24 months, whichever comes first. Standard-Duty Service Inspect the system every 100,000 miles or 12 months, whichever comes first.
18 Heavy-Duty Service Inspect the system every 50,000 miles or six months, whichever comes first. Inspect the following components for correct operation at the recommended inspection intervals. Refer to Section 3 for inspection instructions. ▪ Indicator light ▪ Tire hose valve cores ▪ Tire pressure ▪ Tire hose-to-wheel interference ▪ Tire hose-to-valve stem connections ▪ All air line fitting connections from the pressure protection valve to the axle air fitting ▪ Hubcap vents
19 LANDING GEAR VISUAL INSPECTION BEFORE EACH OPERATION ▪ MISSING COMPONENTS ▪ FASTENERS ▪ CRACKED WELDS ▪ CRACKED METAL LUBRICATION ▪ EVERY THREE MONTHS AFTER MANUFACTURER'S STATED MAINTENANCE FREE PERIOD. PERIODIC INSPECTION EVERY SIX MONTHS ▪ ALL FASTENERS SHOULD BE CHECKED TO ENSURE THAT RECOMMENDED TORQUE VALUES ARE BEING MAINTAINED.
20 BRAKE SYSTEM ABS
21 ABS COMPONENTS
22 BRAKE CHAMBER PERIODIC INSPECTION ▪ MISSING COMPONENTS ▪ DAMAGE TO CAP ▪ EXTERIOR SURFACES FOR DAMAGE , CORROSION AND/OR RUST ▪ CLAMP RINGS ARE SECURED & NOT DAMAGED WHILE SERVICING OTHER COMPONENTS OR EVERY 50,000 MILES ▪ AIR LINES ATTACHED TO CHAMBER ARE NOT DAMAGED OR LEAKING ▪ PUSH-ROD IS SQUARE TO THE BOTTOM OF THE CHAMBER & IS FREE MOVING, NOT BENT, OR BINDING ▪ STROKE INDICATOR CAN NOT BE SEEN ▪ MOUNTING STUDS & JAM NUTS ARE TORQUED PROPERLY.
23 MAXIMUM LEGAL STROKE @ 90-100 PSI APPLICATION PRESSURE CHAMBER TYPE TYPE 30/30 TYPE 30/30 LONG STROKE MAX STROKE 2.0” OR LESS 2.5” OR LESS SLACK ADJUSTER PERIODIC INSPECTION EVERY MONTH, 8,000 MILES OR 300 OPERATING HOURS ▪ CHECK BRAKE CHAMBER PUSH ROD TRAVEL. CHAMBER STROKE SHOULD BE IN COMPLIANCE WITH THE MAXIMUM ALLOWABLE ADJUSTED STROKES WITHOUT THE BRAKES DRAGGING OR THE PUSH ROD BINDING. PERIODIC INSPECTION EVERY SIX MONTHS, 50,000 MILES, OR 1,800 OPERATING HOURS ▪ LUBRICATE ALL SLACK ADJUSTERS & CLEVIS PINS ▪ CHECK FOR WORN CLEVISES & CLEVIS PINS ▪ CHECK FOR WORN OR BROKEN CONTROL ARMS
24 GLAD HAND VISUAL INSPECTION BEFORE EACH OPERATION ▪ Check air pressure ▪ Test the operation of the brake system.
25 ELECTRICAL 7 PIN CONNECTOR VISUAL INSPECTION BEFORE EACH OPERATION ▪ Check the condition of electrical systems like turn signals, dimmer lights, brake lights, and taillights. ▪ Make sure the 7 Pin connector is in perfect working order by inspecting its state. ▪ Check the plug's tightness. ▪ A stable and reliable power supply system should be checked. ▪ Check in the socket if there is water
26 ELECTRICAL SYSTEM COMPONENTS
27 WARRANTY PANUS ASSEMBLY CO., LTD – THAILAND (hereinafter referred as “PANUS TH”) as the manufacturer will assume product liabilities according to the warranty Whereas, PANUS USA LLC (hereinafter referred to as “PANUS USA”) is the sole nominated agent in the USA to be the contact point for receiving all warranty claims within the applicable warranty period as mentioned below. PANUS TH warrants and represents that the chassis will be designed, constructed, composed, painted,marked, tested, and inspected in accordance with the contract specifications as well as drawings referenced below. Without limiting the above, PANUS TH further warrants and represents that the chassis will be sound and free from defects or omissions in design, construction, workmanship, and materials. At its sole option after Buyer notification and due consideration and possible inspection of condition, PANUS TH will replace or repair (including any reasonable direct transportation expenses incurred in moving the chassis to PANUS USA) any part or workmanship product found not in compliance with the warranties and representations stated herein for a five-year period following date of receiving the chassis at PANUS USA facility. This warranty includes decals, plates and markings as originally installed at PANUS TH. PANUS TH, further warrants and represents that the paint system used on the chassis and components will be free from coating failures or defects that result in corrosion or paint failure to the surface of the equipment. Corrosion is defined as condition RE3 of the rust measurement scale over more than ten percent of the chassis surface. At its sole option after Buyer notification and due consideration and possible inspection of condition, PANUS TH will at its option, partially or totally repaint, repair or replace (including any reasonable direct transportation expenses incurred in moving the chassis to PANUS USA) any coating failure as described above for a five-year period following date of acceptance
28 of the chassis by the Buyer. Normal wear and tear, damage from acid / alkaline solutions, and conditions resulting from impact / accident / abrasion are excluded. Warranty Disclaimers: • PANUS TH makes no warranty with respect to the chassis except as stated above. • PANUS TH makes no representation that the chassis are fit for any particular purpose except as described in the specifications. • PANUS TH warranty expressly excludes any and all claims for lost service time or related expenses except as stated above. Coverage is limited to labor and materials for repair / replacement of the affected components and specifically excludes all other costs and losses except transportation as described above. • Any and all damages resulting from abuse, neglect, poor maintenance practices, mishandling, mis-securing, mis-loading, accident, impact, normal wear and tear are excluded. • In the event that a supplier component fails (for example, landing gear, axles, air valves, etc.) PANUS TH will act on behalf of the buyer to repair or replace the defective component, but in no case will PANUS TH extend to the buyer any warranty provisions beyond the terms and conditions offered by the component supplier.
29 CONDITIONS OF THE WARRANTY 1. The warranty will begin on the date you receive the product from PANUS TH as indicated on the invoice (Vehicle delivery certificate) or the date of vehicle delivery as stated in the warranty letter. 2. PANUS TH only warrants the equipment listed in the table below for the warranty period and scope as per OEM Supplier warranty policy # COMPONENTS SUPPLIER WARRANTY PARTS (YEARS / MILES) 1 AXLES AND COMPONENTS 1.1 BEAM AND BRACKETS AXN 5/500,000 1.2 WHEEL ENDS AND BEARINGS STEMCO, SKF or CONMET 5/- 1.3 SEALS STEMCO 5/- 1.4 HUB AXN, STEMCO, SKF or CONMET 5/- 1.5 DRUM AXN Limited Lifetime 1.6 BRAKES SHOE AXN 5 2 BRAKES 2.1 AUTOMATIC SLACK ADJUSTERS HALDEX 6 2.2 30/30 BRAKE CHAMBERS HALDEX 4/UNL 2.3 24/24 BRAKE CHAMBERS FUWA K - HITCH 0.5/- 3 MECHANICAL SUSPENSION AXN 5/500,000 4 PAINT (Zinc rich primer + Topcoat) SHERWIN WILLIAMS 5/- 5 AIR TANKS AXN 1/- 6 TIRE INFLATION SYSTEM PSI / MERITOR 5/- 7 TWIST LOCKS AND PIN LOCKS PANUS TH 5/- 8 HARNESS PHILLIPS 5/- 9 MARKER LIGHTS AND TAIL LAMPS PHILLIPS 3/- 10 7 PIN CONNECTOR PHILLIPS 1/- 11 DOCUMENT HOLDER PHILLIPS 1/- 12 GLAD HANDS PHILLIPS 1/- 13 LANDING GEAR JOST / FUWA 5/- 14 TIRES WESTLAKE 5/- 15 RIMS POMLEAD 5/- 16 DECALS PANUS TH 5/- 17 ABS MODULATOR VALVE KNORR BREMSE - BENDIX 5/- 18 SPRING BRAKE VALVE KNORR BREMSE - BENDIX 1/-
30 HOW TO PROCESS A WARRANTY COMPLAINT AND CLAIM 1. Notify PANUS TH Warranty Administrator by emailing to i[email protected] immediately upon discovery of a defect. 2. Provide the following information: a. VIN Number of the equipment b. Unit number of the equipment c. Model name and number of the equipment d. Invoice number e. Approximate Mileage of the unit f. Detailed description of the problem g. Part number or its serial number if applicable h. Photographs of problem area, where applicable 3. In case of component warranty as per the above list. If the claim is approved under the terms of warranty, PANUS TH will arrange shipment of replacement parts for the damaged components and notify PANUS USA. 4. In case of chassis workmanship related claims approved by the warranty administrator, PANUS TH shall reimburse such cost which would have been incurred in the case of a correction of the respective defect by PANUS USA. QR Code: Warranty claim form Website: www.panusinternational.com Facebook & LinkedIn: Panus International
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