HERCULES

EQUIPMENT
SERVICE MANUAL

Tow Truck Attachment

Model: TA320 (F&R)
Low Bed Mining Trailer
Model: TR-150MT-LB (BF)

Manufactured for:

Sociedad Minera Cerro Verde

Manufactured by:

Hercules Equipment Ltd.

#201-8988 Fraserton Court

Burnaby, Bristish Columbia

Canada V5C 6J5

Phone: (604) 988-9328

Fax: (604) 988-3239

Email: sales@hercules-equipment.com
CONTENTS

1. SPECIFICATIONS
1.1. General Tow Truck (TA-320)
1.2. General Low boy (TR-150MT-LB)

2. INSTALLATION
2.1. Tow Truck Installation
2.1.1. Major Tow Truck Components Distribution
2.1.2. Pivot and Shim Block Assembly
2.1.3. Tow Attachment and Sub-frame Assembly
2.1.4. Counterweight Installation
2.1.5. Tow Pin Assembly
2.2. Low Boy Installation

3. HYDRAULIC SYSTEM
3.1. Tow Truck Hydraulic System
3.1.1. Tow Truck Cylinder
3.2. Low Boy Hydraulic System
3.2.1. Bi-Fold Cylinder
3.2.2. Ramp Cylinder
3.3. Hydraulic Schematic Brake System

4. AIR SCHEMATICS
4.1. Low Boy Air Brake System
4.1.1. Air Brake Circuit
4.1.2. Air Brake Circuit Parts
4.2. Tow Truck Air Schematic

5. ELECTRIC SYSTEM
5.1. Tow Truck Electrical Circuit
5.1.1. Control Panel of Electrical Circuit
5.2. Low Boy Lighting System

6. LOADING AND UNLOADING

6.1. Tow Truck Loading Procedure with Tow Pin
6.2. Tow Truck Loading Procedure with Tow Bar
6.3. Tow Truck Unloading Procedure
6.4. Low Boy Loading Procedure
6.5. Low Boy Unloading Procedure
6.6. Turning Radius

7. 5TH WHEEL OPERATING INSTRUCIONS

7.1. Coupling Procedure
7.2. Uncoupling Procedure

8. PARTS LIST AND DRAWINGS

8.1. Service Spare Parts
8.2. Rim-Wheel Assembly
8.3. Axle Wheel and Components
8.4. Walking Beam Suspension
8.5. Low Boy Ramps Diagram
8.6. Heavy Duty 5th Wheel Diagram
8.6.1. Heavy Duty 5th Wheel Parts List

9. GENERAL MAINTENANCE AND LUBRICATION

9.1. General
9.1.1. New Units
9.1.2. Lubrication Procedures
9.1.3. Grease Lubricated Bearing
9.1.4. To Adjust Brakes
9.1.5. Lining Replacement
9.1.6. Brake Drum
9.2. Axle Bearing Instruction
9.2.1. Suspension Maintenance
9.2.2. Air Chamber Service
9.3. Torque Chart
1. Specifications
1.1. General Tow Truck (TA-320)

MODEL: TA320 Tow Truck Attachment

CAPACITY: Designed to tow empty haulage trucks up to and including 320 ton
class.

GENERAL: Proposed tow attachment is for installation on a Caterpillar 789

haulage truck chassis. A heavy constructed T1 steel sub-frame is
provided and to be secured by pin connection to the box pivot lugs at
rear of chassis and threaded hold- downs at mid-section of the
chassis. The entire attachment can be removed easily from the truck
chassis for truck repair or for mounting on a replacement chassis at
a later date.

HOOK DESIGN: The lift assembly using a single trunnion pin to pick-up disabled
haulage truck from under the front bumper al centre. A special
designed plate/tube tow adaptor will be recessed inside the bumper
with the plate and the tapered opening exposed on the underside of
the bumper.

COUNTERWEIGHT: A 20,000 lbs counterweight package c/w sub-frame for pin

connected to the underside of the front chassis and is removable for
truck engine service. (Note: counterweight box to be supplied by
Hercules. Counterweight material to be supplied by customer to save
shipping cost.)

FENDER: Plate steel fender complete with tool crib, ladder, railing and lights.

HYDRAULIC & The attachment hydraulic system consists of gear flow divider and
AIR PACKAGE directional control valves is suitable for connection to chassis
hydraulic system. In addition to provide auxiliary dumping and brake
release, the unit is also capable of supplying air and 24 VDC to the
disabled truck.

LOAD LOCKING: A special designed load locking mechanism provided for easing the
load on the lift cylinders during towing.

5TH WHEEL: A special duty Jaw-Type, 300 ton rated capacity 5th wheel, Hercules
Model HER-300-HDW. Double locking features (lock jaws and front
locking bar) to ensure a safe yet simple operation.

MISC.: Prime and paint to customer's color choice.

1.2. General Low Boy (TR-150MT-LB)

MODEL: TR-150MT-LB Mining Low Bed Trailer.

TYPE: 16 wheels, single drop, high gooseneck., rear loading

150 metric tons over 5.5 meter wide by 11 meter deck length and is
capable of transporting DK90S Drills, CAT-D11 Dozers or
CAPACITY: equivalent.

DIMENSIONS: As shown on attached sketch.

CONSTRUCTION: T1 main beams, heavy wide flange X-beams.

AXLES: 4 x 60,000 lbs heavy off road type axles c/w 20" by 8" brakes.

Heavy duty fabricated T1 walking beam suspension rated for

SUSPENSION: 240,000lbs capacity c/w rubber bushings.

Standard air brake system c/w type 36/36 spring chamber on all
BRAKES: axles.

WHEELS: Heavy duty Budd tyle alloy steel Wheels, 10 by 13 3/16" bolt circle
TIRES: Michelin or Goodyear 14.00 R 25 off road steel belted radials.

LIGHTS: Tail, brake, turn and side marker lights to be properly protected.

4" thick by 12" wide rough fir approx. 1 1/2" above rails on main bed.
DECKING: Chain and tool storage on upper deck.

Heavy duty king pin c/w skid plate designed for front hook up to a
FRONT HOOK special 5th wheel installed on top of a Hercules TA240(F&R) tow
UP: truck attachment. Chassis supplied by customer.

Special hydraulic operated rear loading ramps one on each side at

the end of the trailer deck approximately 18' long by 7' wide. Heavy
plate steel construction C/W bottom pedestal for maximum stability
LOADING RAMP: during loading and unloading.

Hydraulic operated landing legs c/w positive safety locking feature

LANDING LEGS: to prevent cylinder movement during transportation.
D-RINGS: Heavy cast steel rings four per side of trailer for equipment tie down.
FINISH: Prime and paint CAT Yellow or to customer's colour choice.
TARE WEIGHT: 100,000 lbs approximately.
2. Installation
 2.1 Tow truck installation

SUB-FRAME

AIR CHAMBER: STRUT

3 UNC NUT COUNTERNUT C/W WASHER

TOW ATTACHMENT SUBFRAME

UPPER TOW PIN

TOW HOOK
PIVOT MOUNT

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
COUNTERWEIGHT BOX AND THE CWT SUBFRAME MOUNT.
TITLE :
(CWT BOX SHIPPED EMPTY)
TIE-DOWNS TOW TRUCK INSTALLATION
THIS DRAWING IS PROPERTY OF
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.1 Major tow truck components distribution

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :
THIS DRAWING IS PROPERTY OF MAJOR TOW TRUCK
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
COMPONENTS
WITHOUT PRIOR WRITTEN CONSENT FROM DRAWN BY : DATE : DRAWING NO. :
K-LINE TRAILERS LTD.
 2.1.2 Pivot and Shim Block Assembly

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

Pivot and Shim Block Assembly
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.3 Tow Attachment and Sub-frame Assembly

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

Tow Attachment and Sub-frame
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, Assembly
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.3 Tow Attachment and Sub-frame Assembly

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

Tow Attachment and Sub-frame
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, Assembly
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
2.1.3 Tow Attachment and Sub-frame Assembly

HERCULES EQUIPMENT LTD.

H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

Tow Attachment and Sub-frame
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, Assembly
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.4 Counterweight Installation

CAT 793

bolt weight to
the base with
bolts provided

weld base to weld here

sub-frame

locate counterweight sub-frame

directly under chassis as shown

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

COUNTERWEIGHT
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, INSTALLATION
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.4. Counterweight Installation

weight

lugs

pins baseplate

sub-frame (2 only)

COMPONENTS OF COUNTERWEIGHT PACKAGE

Note:
If these frame rails
miss the chassis add a
cross member under
the sub-chassis frame.
Rest the arm vs. the
cross member, lever
the counterweight by
adding shims to these
two locations.

chassis

HERCULES EQUIPMENT LTD.

H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

COUNTERWEIGHT
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
INSTALLATION
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.4. Counterweight Installation

pin here

flush with sub-frame

four bolts from under

base plate

HERCULES EQUIPMENT LTD.

H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF COUNTERWEIGHT

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
INSTALLATION
WITHOUT PRIOR WRITTEN CONSENT FROM DRAWN BY : DATE : DRAWING NO. :
K-LINE TRAILERS LTD.
 2.1.5 Tow Pin Assembly ( Model 94TP-XL)

P/N 94TP001-XL
TOW PIN (EXTRA LONG
MODEL)

P/N 94TP002
PIN SOCKET (TOP)

P/N 94TP003
PIN SOCKET
(BOTTOM)

P/N 94TP004
BOLT & WASHER KIT

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

PIN ASSEMBLY
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, (MODEL 94TP-XL)
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.1.5 Tow Pin Assembly

STEP #1
front bumper

First cut a round hole in

the middle of the
underside of the front
bumper (hole size
tow pin
sightly larger than O.D.
adaptor
of the tube on the tow
pin adaptor.)

STEP #2
centre of truck

front bumper

weld all around here

TOW PIN WILL

SELF ALIGHN
HERCULES EQUIPMENT LTD.
WITH ADAPTOR
H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

TOW PIN ASSEMBLY
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS DRAWING NO.:
DRAWN BY: DATE:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 2.2 Low Boy Installation

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

LOW BOY
K-LINETRAILERS LTD. INFORMATION CONTAINED
MAY NOT BE USED, REPRODUCED OR
INSTALLATION
DISCLOSED TO OTHERS WITHOUT PRIOR DRAWN BY : DATE : DRAWING NO. :
WRITTEN CONSENT FROM K-LINE TRAILERS LTD.
3. Hydraulic System
 3.1 Tow Truck Hydraulic System

PRE-INSTALLED

02 C1A C2B
BY CUSTOMER C1B C2A

20-40 GPM @ 2200 PSI

01
03
ITEM DESCRIPTION PART NO. QTY.
01 FLOW CONTROLLER FD-75.1.75-1.2 01
02 CONTROL VALVE 2001116TAH002 01
03 JUNCTION BOX 94TAH003 01

TO AUXILLARY
DUMPING

110 GPM

110 GPM

RETURN TO TANK
RETURN TO TANK

SPECIAL NOTE:
CAT 789 / 793 HOIST PUMP (TWIN) HERCULES EQUIPMENT LTD.
OUTPUT 220GPM MAX. @ 2350 PSI (USE BURNABY, BC, CANADA
ONE SIDE OF THE PUMP ONLY, DO NOT H Tel: 604.988.9328 Fax: 604.988.3239
DEADEND RETURN LINE!) www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF TOW TRUCK HYDRAULICS

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
(FOR CAT 789/793 CHASSIS)
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.1.1 Tow Truck Cylinder

SEAL KIT # 11890 INCLUDES ITEMS 1 TO 8

ITEM DESCRIPTION PART NO. QTY.

01 PISTON SEAL 11015 02 SERIES-B HYDRAULIC CYLINDER
02 WEAR RING 11655 01 BORE: 10"
03 O-RING 10173 01 STROKE: 50"
04 HEAD SEAL 10276 01
05 B/U RING 10277 01
MODEL: H261-50
06 WEAR RING 11638 01
07 ROD SEAL 10434 01
08 WIPER 12061 01
09 LOCK NUT 11978 01
10 PISTON B960 01
11 BARREL
HERCULES EQUIPMENT LTD.
H261-B 01
12 ROD BURNABY, BC, CANADA
H261-R 01
B1915
H Tel: 604.988.9328 Fax: 604.988.3239
13 HEAD 01
www.hercules-equipment.com
14 BOLT KIT 11987 01
TITLE :
15 SPHERICAL BRG 11551 02
THIS DRAWING IS PROPERTY OF TOW TRUCK CYLINDER
K-LINETRAILERS LTD. INFORMATION 16 SNAP RING 11750 02
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS 17 MANIFOLD MB1013-S 01
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD. 18 CARIRIDGE CBEA-LHN 01
 3.2 Low Boy Hydraulic System
06

BI-FOLD CYLINDER (2)

ITEM DESCRIPTION PART NO. QTY. 04

01 HYDRAULIC LANDING LEG 300465 02
02 CONTROL VALVE-DOUBLE BANK 60VS03A-5C1-02Y-H8VA20 01
03 CONTROL VALVE-DOUBLE BANK 60VS03A-5D1-AAB18B18-5D1-02Y-H8VA20 01
04 CONTROL VALVE-SINGLE BANK 60VS03A-5D1-AAB18B18-5D1-03T-H8VA20 01
05 H3128-18 04
05
06 H3163-24 04
07 QUICK COUPLER - MALE NS561-6 01
08 QUICK COUPLER -FEMALE NS565-6 01
09 FLOW CONTROL - 1/2 " PARKER - F 02

09
07
RAMP CYLINDERS

20-40 GPM @ 2200 PSI

BI-FOLD CYLINDERS (2)
03
08

02

09

RAMP CYLINDERS
01

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF LOW BOY HYDRAULIC

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
SYSTEM
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.2.1 Bi-Fold Cylinder

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF BI-FOLD CYLINDER

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.2.2 Ramp Cylinder

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF RAMP CYLINDER

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.2.2 Ramp Cylinder

CYLINDER SPECIFICATIONS

BORE________________________________________________5.00 IN
ROD_________________________________________________3.50 IN HERCULES EQUIPMENT LTD.
WORKING STROKE___________________________________36.00 IN
TOTAL STROKE______________________________________43.00 IN BURNABY, BC, CANADA
STOP TUBE__________________________________________7.00 IN H Tel: 604.988.9328 Fax: 604.988.3239
MOUNTING HEIGHT__________________________________18.38 IN www.hercules-equipment.com
WEIGHT (DRY)______________________________________XXX LBS TITLE :

THIS DRAWING IS PROPERTY OF

OPERATING PRESSURE EXTEND/RETRACT_________2500/2500 PSI
K-LINETRAILERS LTD. INFORMATION LIFTING CAPACITY_________________________________ 70000 LBS
RAMP CYLINDER
CONTAINED MAY NOT BE USED, SIDE LOAD________________________________________ 7700 LBS
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.2.2 Ramp Cylinder

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF RAMP CYLINDER

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 3.3. Hydraulic Schematic Brake System

3 ITEM DESCRIPTION PART NO. QTY.

01 POWER UNIT DELTA HP-109-24-Vdc 01
02 ACCUMULATOR 1 QT. ACCUM. INC. A1QT-3100-3 01

PLUG 1 03
04
PRESSURE SWITCH
PRESSURE GAUGE
HERION 08--823-20
LHA PGL-A-63-N-B-3000-S
01
01

4 05 H.P. BALL VALVE LHA HBV-06-S 01

HERCULES EQUIPMENT LTD.

H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:
THIS DRAWING IS PROPERTY OF HYDRAULIC SCHEMATIC
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
BRAKE SYSTEM
WITHOUT PRIOR WRITTEN CONSENT FROM DRAWN BY: DATE: DRAWING NO.:
K-LINE TRAILERS LTD.
4. Air Schematics
 4.1 Low Boy Air Brake System

ITEM DESCRIPTION PART NO. QTY.

01 EMERGENCY GLADHAND (RED) GHE 01
02 SERVICE GLADHAND (BLUE) GHS 01 HERCULES EQUIPMENT LTD.
03 QUICK RELEASE VALVE QR1-VA-229859 04 BURNABY, BC, CANADA
04 RELAY EMERGENCY VALVE 110470 02 H Tel: 604.988.9328 Fax: 604.988.3239
05 AIR TANK 2002D 04 www.hercules-equipment.com
TITLE:
06 AIR TANK AT-001 04
THIS DRAWING IS PROPERTY OF
K-LINETRAILERS LTD. INFORMATION
07 AIR POT A4075-07 08 LOW BOY AIR BRAKE SYSTEM
CONTAINED MAY NOT BE USED, 08 LINE FILTER: 3/8 A4075-08 01
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 4.1.1 Air Brake Circuit

07

JUNCTION BOX

TOW TRUCK
AIR CHAMBER
CABIN

SUPPLY.
04
SERV.
SERVICE
SERV.

DEL 05
EMERG. 06

EMERG.

SUPPLY.
09

CONTROL
DEL 03

INLET

EXHAUST

MAIN OUTLET DEL

AIR
02
08 INLET
TANK

01

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF AIR BRAKE CIRCUIT

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
4.1.2. Air Brake Circuit Parts

Part Description
Number
1 KN20561 Hand Valve

2 KN20031 Hand Push-

pull Valve

3 KN200025 Trailer Supply

Valve

4 CAT 789
Truck Air Tank
in Cabin
5 283940X R6 Relay Valve

6 KN34050 Tractor
Protection

7 Air Tank
supplied by
Hercules
8 Principal
Truck CAT
793 Air
Chamber
9 15’ COIL AIR
LINE 11-315
 4.2 Tow Truck Air Schematic

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION TOW TRUCK AIR SCHEMATIC
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
5. Electric System
 5.1. Tow Truck Electrical Circuit

MAIN
POWER

CABINET LAMP

BREAK POWER PACK

LIGHT

BREAK POWER PACK COIL

BREAK POWER
PACKMOTOR

STRUT CONTROL

LIFT CYLINDER UP

AUX DUMP P PORT

LIFT CYLINDER DOWN

AUX DUMP T PORT

HERCULES EQUIPMENT LTD.

H BURNABY, BC, CANADA
Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION
TOW TRUCK ELECTRICAL CIRCUIT
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
FOR 2007 AND NEWER MODELS
WITHOUT PRIOR WRITTEN CONSENT FROM DRAWN BY : DATE : DRAWING NO. :
K-LINE TRAILERS LTD.
 5.1.1. Control Panel of Electrical Circuit

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

CONTROL PANEL OF
K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, ELECTRICAL CIRCUIT
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
5.1.1. Control Panel of Electrical Circuit ( Material List)

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
 5.2 Low Boy Lighting System

03 03 03 04
03

05
01

06
07
02
06

09 07
02
09 08 06 02

01

ITEM DESCRIPTION PART NO. QTY.

01 44302R 02
02 44302R 02
03 44203Y 08
04 44302R 02
05 JUNCTION BOX PHILLIPS 15-961 03
06 7-WIRE SOCKET PHILLIPS 15-720 04
07 7-WIRE PLUG PHILLIPS 15-730 03
08 4-WIRE SOCKET PHILLIPS 15-400 01
09 4-WIRE PLUG PHILLIPS 15-430 01

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION
LOW BOY LIGHTING SYSTEM
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
6. Loading and Unloading
6.1. Tow Truck Loading Procedure with Tow Pin

a) With tow hook at near ground position back tow truck toward the disabled truck.

b) With the assistance from the 2nd driver (from disabled truck), slowly position tow pin
right under tow pin adapter at the underside of the disabled truck (slightly off center
is okay).

c) Using the control pendant (c/w 30’ cable) located inside the tool box, slowly lift the
tow hook by pressing the lift button. If lifting is too slow or too fast, change the
cylinder speed by turning the control dial at the control panel inside the tool box.

d) Tap de tow pin into position with a hammer slightly if the tow pin miss the adapter
hole during lifting.

e) As the front of the disabled truck starting to raise, carefully observe the alignment
between the tow pin and the tow adapter. If too much out of center it is wise to
lower the tow hook and retry after reposition the tow truck.

f) The strut (vertical support) located near the mid-section of the tow hook will swing
to vertical position as soon as the front of the disabled truck has reached the
expected height.

g) As soon as ta “cling” sound is heard, release the lift button at the control pendant.

h) Lower the cylinder slowly.

i) Stop cylinder movement at once as soon as the strut has fallen into position inside
the strut saddle right underneath the strut.

j) Release down button and put control back inside tool box, loading is complete.

k) Now tow truck is ready to go.

Tow Pin and Tow Adaptor
6.2. Tow Truck Loading Procedure with Tow Bar

a) With tow hook at near ground position, back up the tow truck toward the disabled
truck.

b) With the help of a crane, slowly position the Tow Bar on top of the tow pin.

c) Position the Tow Bar under the bumper of the disabled truck and using the
control pendant (c/w 30’ cable) located inside the tool box, slowly lift the tow hook
by pressing the lift button. If lifting is too fast or too slow, change the cylinder speed
by turning the control dial at the control panel inside the tool box.

d) As the front of the disabled truck starts to raise, carefully observe the alignment
between the tow pin and the Tow Bar. If too much out of center it is recommended
to lower the tow hook and retry after repositioning the tow truck.

e) The strut (vertical support) located near the mid-section of the tow hook will swing
to vertical position as soon as the front of the disabled truck has reached the
expected height.

f) As soon as a “cling” sound is heard, release the lift button at the control pendant.

g) Lower the cylinder slowly.

h) Stop cylinder movement at once as soon as the strut has fallen into position
inside the strut saddle right underneath the strut.

i) Release the down button and put the control back inside tool box; loading is
complete.

j) Now the tow truck is ready to go.

6.3. Tow Truck Unloading Procedure

a) Using the control pendant slowly raise the lift cylinder.

b) Stop cylinder movement as soon as the strut has cleared the strut saddle.

c) Press the strut kick-out button.

d) Lower the tow hook by pressing the cylinder down button. The strut will follow the
profile of the saddle and kick itself out toward the back.

e) Lower tow hook until disabled tow truck is on the ground.

f) Before driving away make sure tow pin has fully disengaged from the tow pin
adapter at the disabled truck.

g) Unloading is complete.
6.4. Low Boy Loading Procedure

Your Hercules Lowbed Mining Trailer equipped with special heavy duty wide pad rear
loading ramps provide very gentle loading profile for loading and unloading of your heavy
equipment. It is wise to select an area that is as level as possible and also a surface that
will handle the load imposed on the rear ramps. Approximate ground pressure with a 100
ton load would be 80 to 90 PSI per side.

a) Back tractor to trailer front slowly with 5th wheel engaged with trailer king pin. Lock
5th wheel jaw.

b) Raise landing legs.

c) Re-connect air, electric and hydraulic lines.

d) Lower rear loading ramps slowly.

e) Drive equipment onto the main deck via the rear loading ramps.

f) Retract loading ramps, lock ramps in up position.

g) Securely tie equipment down on side rail of trailer.

h) Slowly drive away, DO NOT EXCEED 10 MPH WHEN TRAILER IS FULLY

LOADED.
6.5. Low Boy Unloading Procedure

a) Connect trailer hydraulic to the chassis hydraulic with the quick couplers provided.

b) Check if rear of trailer is clear and disengage ramp locks before slowly lower rear
loading ramps. The hydraulic control valve is located near the end of the trailer
main deck, on driver’s side.

c) Slowly drive equipment off trailer through the rear of the trailer.

d) After unloading, retract loading ramps to up position; lock ramps with steel bar
provided.

e) To unlock trailer from tractor, please do not forget to:

a. Lower landing legs
b. Disconnect air lines, hydraulic lines and electric lines from tractor
c. Unlock 5th wheel jaw

f) Drive tractor slowly away from trailer.

 6.6 Turning Radius

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION TOW TRUCK AIR SCHEMATIC
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE: DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
7. 5th Wheel Operating Instructions
7.1. Coupling Procedure

WARNING: A fully oscillating fifth wheel such as the Hercules Model HER-300-HDW is
less stable than a conventional semi-oscillating fifth wheel which will result in different
handling characteristics. Extreme caution should be exercised when cornering or making
lane changes, etc.

1. Make sure that the 5th wheel top plate is properly lubricated, that the 5th wheel top
plate leading ramps are tilted down, and that the fifth wheel locks are open.

2. Back tractor up close to the trailer, centering the kingpin on the throat of the fifth
wheel, STOP.

3. Block the trailer wheels, connect the air brake lines, the hydraulic lines and the 7-
pronge 24 VDC light cord. Be sure to any slack in the lines is supported so the
brake lines do not become tangles. Set the trailer brakes.

4. Check to see in the trailer skid plate (upper coupler plate) is at the proper height for
coupling. The leading edge of the skid plate on the trailer should initially contact the
fifth wheel leading ramps at the throat of the fifth wheel. Adjust the kingpin height to
suit the fifth wheel height by raise of lower the trailer hydraulic landing legs as
requires obtaining a suitable coupling position. NEVER RAISE OR LOWER THE
HYDRAULIC LANDING LEGS WHEN THE TRAILER IS LOADED.

5. Back under the trailer, keeping the kingpin centered in the throat of the fifth wheel.

6. After picking up the trailer with the fifth wheel, STOP, then continue backing until
the fifth wheel loacks firmly on the kingpin. Stopping helps prevent hitting the
kingpin too hard.

7. Back up tightly against the kingpin. Then pull forward slightly to test is the kingpin is
fully coupled and locked by the lock jaws inside the fifth wheel.

8. When the kingpin is fully coupled, apply both the safety bar and the lock jaw bar to
jam locks the lock jaw and the kingpin.

9. Retract hydraulic landing legs.

10. Check all electric cord, hydraulic and air brake lines.

11. Remove the wheel blocks and continue with standard routine pre-trip inspection.
7.2. Uncoupling Procedure

1. Set trailer brakes.

2. Block trailer wheels.

3. Lower hydraulic landing legs.

4. Disconnect the light cord, hydraulic lines and the air brake lines.

5. Unlock the lock jaws by releasing both the safety bar and the lock jaw bar.

6. Pull trailer out slowly. Let the trailer slide down the fifth wheel and the leading
ramps, being careful that the trailer landing gear touches the ground with minimal
impact.

7. Slowly drive tractor away.

8. Parts Lists and Drawing
8.1. Service Spare Parts

ITEM PART NO. DESCRIPTION QTY

1 B5KX01 6" dia. X 70" track axle beam 4
2 B5KX02 Air chamber bracket 8
3 B5CR03 Trunnion clamp assembly 2
4 B5CR04 Trunnion stud bolt 16
5 B5CR05 Trunnion cap 4
6 B5CR06 Nut 32
7 B5CR07 Rubber bushing-trunnion mount 4
8 B5CR08 Walking beam assembly (MODEL WB150) 2
9 B5CR09 Spacer washer 4
10 B5CR10 Rubber bushing-axle mount 4
11 B5CR11 Compression stud 4
12 B5CR12 Compression cap 4
13 B5CR13 Flat Washer 4
14 B5CR14 Compression nut 4
15 B5CR15 Jam nut 4
16 B5CR16 Jam nut 16
17 S6KX17 Hub cap bolt 48
18 S6KX18 Hub cap lockwasher 48
19 S6KX19 Hub cap 8
20 S6KX20 Spindle nut locking bolt 8
21 S6KX21 Spindle nut 8
22 S6KX22 Spindle "D" washer 8
23 S6KX23 Hub cap gasket 8
24 B5KX24 Heavy duty wheel hub 8
25 B5KX25 Wheel stud RH 40
26 B5KX26 Wheel stud LH 40
27 B5KX27 Wheel stud nut 80
28 B5KX28 Wheel stud flat washer 80
29
30 B5KX30 Brake drum 8
31 B5KX31 Lines shoe (items 32, 33 & 38) 16
32 6KX32 Brake block FMS 4350 32
33 S6KX33 Brake shoe 16
34 S6KX34 Brake return spring 8
35 S6KX35 Brake shoe roller 16
36 S6KX36 Brake shoe roller pin lock 16
37 S6KX37 Brake shoe roller pin 16
38 S6KX38 Brake block bolt, but & lockwasher set 96
39 B5KX39 Outer bearing cup 8
40 B5KX40 Outer brearing cone 8
41 B5KX41 Inner bearing cup 8
42 B5KX42 Inner bearing cone 8
43 B5KX43 Cam shaft RH 4
44 B5KX44 Cam shaft LH 4
45 S6KX45 Grase retainer 8
46 S65KX46 Camshaft washer 8
47 S6KX47 Cam shaft seal 8
48 S6KX48 Cam shaft housing & bracket 8
49 S6KX49 Cam shaft spring 8
50 S6KX50 Slack adjuster RH 4
51 S6KX51 Slack adjuster LH 4
52 S6KX52 Cam shaft retaining washer 8
53 S6KX53 Cam chaft lockwasher 8
54 S6KX54 Cam shaft retaining bolt 8
55 S6KX55 Anchor pin grease fitting 16
56 S6KX56 Anchor pin lock 32
57 S6KX57 Grease retaining ring 8
58 S6KX58 Anchor pin 16
59 S6KX59 Brake shoe bushing 32
60
61 B5KX61-KL Anchor 8
B5KX62-
62 CBS Air chamber - Type 36/36 8
63
64 B5KX64 Inner wheel nut RH 40
65 B5KX65 Inner wheel nut LH 40
66 B5KX66 Outer wheel nut RH 40
67 B5KX67 Outer wheel nut LH 40
68
69
70 S6KX70 Anchor bolt 32
71 S6KX71 Anchor bolt lockwasher 32
72 S6KX72 Anchor bolt nut 32
73 B5KX73 Rim-wheel assembly (not shown) 16
74 B5KX74 14.00 x 25 off-road tires 16
 8.2 Rim-Wheel Assembly
28
30 27

25
64 26
66 65
67 54
57 53
45 50 52
42 51
41 49
48

24
39
40 47 1
2
22 46 62
21
44 13
20 43
23
19
18 34
17 36
32

71
72 31
32
35 36 37 33
56 55 58 61 70 38

59

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION RIM-WHEEL ASSEMBLY
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 8.3 Axle Wheel and Components

WHEEL
STUD NUT

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF

K-LINETRAILERS LTD. INFORMATION AXLE WHEEL AND COMPONENTS
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 8.4 Walking Beam Suspension

8
7
5

6 15
16 14
13
12
11

10 HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
9 H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF WALKING BEAM SUSPENSION

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 8.5 Lowboy Ramps Diagram

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF LOWBOY RAMPS DIAGRAM

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED,
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 8.6 Heavy Duty 5th Wheel Diagram
03

05 01
04

06

02

07

NOT SHOWN:
12 Bottom swivel plate
Bottom pivot pin
Bottom pivot pin keeper
6.0" king pin

14
HERCULES EQUIPMENT LTD.
09 BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE:

THIS DRAWING IS PROPERTY OF Heavy Duty 5th Wheel Diagram

K-LINETRAILERS LTD. INFORMATION
CONTAINED MAY NOT BE USED, 10
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY: DATE: DRAWING NO.:
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
 8.6 Heavy Duty 5th Wheel Diagram
RELEASE LEVER BOLT, WASHER & NUT SET
LOCK JAW
BAR

LOCK JAW, L & R

KING PIN

BOTTOM SWIVEL
PLATE

TOP PLATE SAFETY

BAR

PIVOT PIN,
TOP SWIVEL

BOTTOM PIVOT PIN

HERCULES EQUIPMENT LTD.

BURNABY, BC, CANADA
H Tel: 604.988.9328 Fax: 604.988.3239
www.hercules-equipment.com
TITLE :

THIS DRAWING IS PROPERTY OF

HEAVY DUTY 5TH WHEEL
K-LINETRAILERS LTD. INFORMATION TOP SWIVEL PLATE
CONTAINED MAY NOT BE USED, DIAGRAM
REPRODUCED OR DISCLOSED TO OTHERS
DRAWN BY : DATE : DRAWING NO. :
WITHOUT PRIOR WRITTEN CONSENT FROM
K-LINE TRAILERS LTD.
8.6.1. Heavy Duty 5th Wheel Parts List

ITEM PART NO. DESCRIPTION QTY

1 FW-001/6" Fifth wheel plate 1
2 FW-002/6" Lock jaws (set of 2, L&R) 1
3 FW-003/6" Bolt washer and nut set 1
4 FW-004/6" Lock jaw bar 1
5 FW-005/6" Release lever 1
6 FW-006/6" Lever spring 1
7 FW-007/6" Pivot pin (top pivot) 2
8 FW-008/6" Pin keeper (top pivot) 2
9 FW-009/6" Safety bar 1
10 FW-010/6" Handle and weight 1
11 FW-011/6" Bottom plate 1
12 FW-012/6" Top swivel plate 1
13 FW-013/6" Bottom pivot plate 1
14 FW-014/6" Pin keeper (bottom pivot) 1
15 FW-015/6" 6.0" kingpin, new style removable 1
9. General Maintenance and Lubrication
9.1. General

Proper maintenance and lubrication at regular intervals, depending on usage of road

conditions, will assue good service with a minimum necessity of parts replacement.

It is recommended that grease fittings be lubricated every 2,000 miles, or more frequently
when units are operated on dusty unimproved roads, or in extremely wet conditions.
Wheel bearings and hubs should be cleaned and replaced at regular intervals depending
upon usage.

9.1.1. New Units

When new axles are placed in service, it is important that wheel nuts are checked and
tightened after the first 50 miles of operation. Wheel bearing adjustment should be
checked after the first 500 miles of operation, and wheel nuts rechecked and tightened.
Check brake adjustments before and while burnishing-in.

9.1.2. Lubrication Procedures

Grease camshaft housing with chassis lubricant recommended for prevailing

tmeperatures. Caution should be taken not to over lubricate the anchor pin so that grease
falls on the brake drum or brake block.

9.1.3. Grease Lubricated Bearings

To lubricate wheel bearings:

 Jack up axle sufficiently for wheels to clear ground.
 Remove hub cap, splindle nuts, and pull hub and drum assembly froward until it is
free from the axle spindle.
 Remove inner bearings from spindle and inspect grease retainer to see that seal
ring is free.
 Clean bearings, very thoroughly, with cleaning solvent ( mineral spirits), and dry the
bearings. No not use compressed air for this purpose.
 Inspect bearings for pits, chipping or wear; replace if necessary.
 Inspect brake drums for scoring. If drums are scored, they must be tirned smooth
or replaced.
 Inspect brake lining for wear, check brake shoe pullback springs, and pins and
rollers for wear or breakage; replace as necessary.
 Bearings should be repacked with wheel bearing grease suitable for prevailing
temperatures. In packing bearings, the lubricant must be packed carefully between
the rollers, by hand or with a packer, and must not be just spread on the outside.
Care must be excercised to see that dirt, grit, lint or other contaminants do not get
in the bearings.

 Remove all old grease from inside hub and wash with cleaning solvent (mineral
spirits) and dry thoroghly. Inspect cups for wear, pits or scratches; if any of this is
evident, replace the cups. Fill the space in the hub between the two bearing cups
with grease.
  Remove all old grease from the axle spindle with cleaning solvent (mineral spirits).
After drying, spread a thin coat or grease over spindle.

 When reassembling, care should be taken to see that the inner bearing is properly
seated. Slide the hub and drum assembly onto axxle spindle and push into
position. Be sure to support properly, so as to avoid damaging spindle threads.
Install outer bearings, spindle nuts and hub cap.

 To adjust bearings, tighten the spindle nut and turn hub and drum assembly to
assure proper seating of bearing. The bearing should be adjusted in accordance
with attached procedure.

9.1.4. To Adjust Brakes

Jack up axle so that the wheel clears ground, turn adjusting nut on slack adjuster
clockwise until wheel cannot be moved, then back off aproximately ½ turn until wheel rolls
free. Recheck during and after initial burnishing-in stops. When the brakes are fully
applied, the angle between the push rod and the arm of the slack adjuster should not be
less than 90º (a right angle).

9.1.5. Lining Replacement

At regular intervals, depending on usage and oad conditions, it is necessary to inspect

brake lining for wear. The thisckness of the block, when new is ¾ inch, and can be worn
down to the heads of the rivets or aproximately 3/16 inches. It is always advisable to clean
and repack the bearings when replacing lining.

9.1.6. Break Drum

With proper adjustment of brakes and bearings, replacing lining when needed, it is seldom
necessary to replace brake drums. However, to prolong life of drums, the following should
be watched:
  Avoid setting brakes in standing position when drums are excessively hot, as the
drum cooled with brake stes are sometimes distorted causing premature failure.
 Avoid striking water or fording streams when drums are excessively hot, as the
sudden shill can cause premarure failure.

If drums show excessive heat, they should be turned smooth not to exceed 0.120
oversize. Cracked drums must be replaced.
9.2. Axle Bearing Instruction

1. Heat combined bearing retainer and labyrinth grease seal to approximately 600ºF (blue
color) to expand hole. Slide retainer on spindle (radius side in against axle shoulder)
nd hold against shoulder until “set”. Let cool.

2. Grease labyrinth grooves in seal and put expansing ring in place. Lightly grease
spindle.

3. Pre-pack bearings with correct grease.

A. Normal temperature: NLGI #2
B. Severe cold: DN 600 Conoco or equal

4. Put inner bearing on and tap firmly up against axle shoulder or retainer acting as a
spacer.

5. Pack spindle with grease.

6. Pack hub/wheel with grease.

7. Install hub / wheel

8. Place outer bearing in hub / wheel.

9. Put on “D” washer.

10. Screw on nut by hand – tap on end to assist thread fit.

11. Tighten nut to 400 ft. punds while turning hub/wheel to seat bearings.

12. Back off spindle nut ¼ turn plus any additional necessary to line up locking pin holes.

13. Install locking pin / bolt.

14. Put on locking pin / bolt, small washers and nut, tighten snug and peen over end of bolt
to stop small nut from backing off.

15. Put on gasket and hub cap.

9.2.1. Suspension Maintenance

The 300,000 lb walking beam suspension incorporates rubber bushings at all connection
points to the axles and the trunnion shaft. No lubrication is required, however, it will be
necessary to ensure that all U-bolts are tightened to the required torque ratings. After the
unit has been in service for aproximately 500 miles, all U-bolt-torques should again be
checked, and then at the 2,000 mile interval. The following torques should be maintained:

Bolt. Diam. Torque (Ft-Lbs)

¾” 150
1” 400
1-1/8” 700
1-1/4” 1000
1-3/8” 1200

9.2.2. Air Chamber Service

If air chamber service should be required, the dis-assembly procedure of the chamber
units is attached. Care should be exercised when working with air chambers and the
instructions to release the brake chambers, should be closely followed.
9.3. Toque Chart

STUD BOLT RECOMMENDED

APPLICATION SIZE AND TORQUE IN
THREAD FOOT POUNDS
OFF THE ROAD VEHICLES DISC WHEELS
BUDD STANDARD MOUNTING, COUNTERSUNK HOLES 3/4" - 16 450-500
BUDD STUDS - THAT USE BACK NUTS 1 1/8" - 16 450-500
BUDD STUDS - WITH HEADS - NO BACK NUTS 1 1/8" - 16 650-700
BUDD 3/4" STUDS WITH 7/8" OR 1" BACK NUTS 1 1/8" - 16 650-700
BUDD HEAVY DUTY MOUNTING 15/16" - 12 750-900
BUDD HEAVY DUTY MOUNTING 5/16" - 12 750-900
BACK NUTS OR INNER END OF WHEEL STUD 7/8" - 14 175-200
BACK NUTS OR INNER END OF WHEEL STUD 1" - 14 175-200
CAST WHEELS
CAST WHEELS - DEMOUNTABLE RIMS 3/4" - 10 225
CAST WHEELS - DEMOUNTABLE RIMS 1" - 8 450
CAST WHEELS - DEMOUNTABLE RIMS 1" - 14 450

IMPORTANT

*WHEN INSTALLING WHEEL CLAMPS IT IS MOST IMPORTANT TO ADHERE TO THE

ABOVE TORQUES, WHICH VARY WITH ATUD SIZE, SO THAT THE CLAMP IS
PROPERLY TIGHTENED AND THE CLAMP HEEL PROPERLY POSITIONED ON THE
WHEEL.

*THE THREADS OF THE STUDS, BOLTS AND NUTS AND THE BEARING SURFACE
SHOULD BE CLEAN, DRY AND FREE FROM OIL OR GREASE WHEN TORQUED TO
THE SPECIFIED FOOT POUNDS. DO NOT LUBRICATE.

*FREQUENT TORQUE CHECKS, SHOULD BE MADE, ESPECIALLY AFTER EVERY

CHANDE IN WHEEL OR RIM MOUNTING.