manualshive.com logo in svg

Demco CR 108, Operator'S Manual, Page: 2 / 104

Share
Download
Demco CR 108 Operator'S Manual Download Page 2

2

Table of Contents 

Introduction...........................................................................................................................  

4

Dealer Checklist....................................................................................................................  

6

To The Owner........................................................................................................................  

7

Safety....................................................................................................................................  

8

Torque Requirements............................................................................................................          12-13

Safety Decals........................................................................................................................          14-15

Coupling/Uncoupling.............................................................................................................          15-21

Operating Instructions...........................................................................................................  

22

Pre-Trip Checklist..................................................................................................................  

23

Maintenance Check List........................................................................................................         24-26

Full Function Anti-lock Brake System...................................................................................          27-28

Haldex Brake System Troubleshooting Guide......................................................................          29-35

Adjustment and Operation of Brakes....................................................................................          36-37

Tires......................................................................................................................................  

38

Wheels Installation................................................................................................................  

39

Wheel Maintenance During Tire Inspection..........................................................................  

40

Axle Inspection......................................................................................................................  

41

Suspensions.........................................................................................................................  

42

Suspension Torque Specification..........................................................................................  

43

Troubleshooting Electrical System........................................................................................  

44

Troubleshooting General.......................................................................................................           45-49

Parts

SS-102-4LS, Tandem Spring Ride Converter Dolly..............................................................           50-55

Converter Dolly Tongue 33-1/2”............................................................................................           56-59

Converter Dolly Tongue 78”..................................................................................................           60-63

Converter Dolly Tongue 108”................................................................................................           64-67

Converter Dolly Tongue 120”................................................................................................           68-71

Converter Dolly Tongue 133”................................................................................................

           

72-75

ABS Brake Parts...................................................................................................................  

76

Hutch Suspension Kit............................................................................................................           77-78

7700/9700 4-Spring Maintenance.........................................................................................           79-83

Hub Pilot Axles......................................................................................................................           84-104

Summary of Contents for CR 108

Page 1: ...E DUMP CONVERTER DOLLY CR 33 5 Converter Dolly Tongue CR 78 Converter Dolly Tongue CR 108 Converter Dolly Tongue CR 120 Converter Dolly Tongue CR 133 Converter Dolly Tongue SS 102 4LS Converter Dolly...

Page 2: ...s 36 37 Tires 38 Wheels Installation 39 Wheel Maintenance During Tire Inspection 40 Axle Inspection 41 Suspensions 42 Suspension Torque Specification 43 Troubleshooting Electrical System 44 Troublesho...

Page 3: ...safety so this is not advised If a replacement part is necessary Demco should supply it please contact your nearest dealer or Demco DEMCO STATEMENT OF PRODUCT SAFETY As a producer of agricultural and...

Page 4: ...ble free operations Proper maintenance adjustments and use will result in many years of service Keep this manual handy for frequent reference and to pass on to new operators or owners If assistance in...

Page 5: ...leted warranty registration form Fax 712 262 1022 Register on line in warranty page at www demco products com Complete and return registration form Demco Warranty does not cover the following 1 Cleani...

Page 6: ...is a reminder of points to cover Check off each item as it is found satisfactory or after proper adjustment is made DELIVERY Review the operator s manual with the customer Explain the following 1 Saf...

Page 7: ...st you in the operation of your new trailer and contains information pertaining to safety operations and all of its parts Our personnel in sales and service arealwaysavailabletoassistyouwhenquestionsa...

Page 8: ...fect machine life PROTECT CHILDREN AND BYSTANDERS Before you back LOOK CAREFULLY behind for children Clear area of children pets and bystanders HIGHWAY AND TRANSPORT OPERATIONS Adopt safe driving prac...

Page 9: ...ing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Prot...

Page 10: ...ury It may also be used to alert against unsafe practices EQUIPMENT SAFETY GUIDELINES Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful appro...

Page 11: ...of unit The inspection of the tire and wheel lug nuts is necessary since they are prone to loosen after first being assembled Please follow the list of guidelines and or possibilities below that could...

Page 12: ...00 540 7 8 170 230 420 570 650 880 1 225 300 630 850 970 1310 Torque figures indicated are valid for non greased or non oiled threads and heads unless otherwise specified Therefore do not grease or oi...

Page 13: ...the fasteners matched to the cone angle of your wheel usually 60 degrees or 90 degrees The proper procedure for attaching your wheels is as follows 1 Start all bolts or nuts by hand to prevent cross...

Page 14: ...or removed Block all wheels AP 3673 DANGER EMERGENCY PARKING BRAKE HAZARD To prevent serious injury or death from parts explosion Springbrakechamber must be caged or deactivated before servicing AP 3...

Page 15: ...er 4 Remove smallest portion of split backing paper 5 Align decal over specified area and carefully press the small portion with the exposed sticky backing in place 6 Slowly peel back remaining paper...

Page 16: ...because of friction between the tractor and the trailer Check if fifth wheel is in proper position for coupling Wheel tilted down towards rear of tractor Jaws open Safety unlocking handle in the auto...

Page 17: ...m cab push in air supply knob or move tractor protection valve control from the emergency to the normal position to supply air to the trailer brake system Wait until the air pressure is normal Check b...

Page 18: ...t Make sure air and electrical lines will not hit any moving parts of the vehicle Coupling and Uncoupling WARNING Hydraulic fluid escaping under pressure can have enoughforcetopenetratetheskin Hydraul...

Page 19: ...e shank of the kingpin Check that the locking lever is in the lock position Check that the safety catch is in position over locking lever On some fifth wheels the catch must be put in place by hand If...

Page 20: ...wing steps will help you to uncouple safely Step 1 Position Rig Make sure surface of parking area can support weight of trailer Have tractor lined up with the trailer Pulling out at an angle can damag...

Page 21: ...e handle lock Pull the release handle to open position Keep legs and feet clear of the rear tractor wheels to avoid serious injury in case the vehicle moves Step 6 Pull Tractor Partially Clear of Trai...

Page 22: ...ge are also on a decal located on the trailer sub frame above the suspension 2 Re torque all wheel lug nuts 3 Check all clearance lights turn signal indicators and stop lights 4 Inspect all brake hose...

Page 23: ...latches to ensure they are both set for dumping to the same side Daily Inspection Checklist Perform the Daily Inspection Checklist each day before operating your side dump trailer 1 Preform the Pre T...

Page 24: ...week 1 Perform the Pre Trip and Daily Inspection Checklists 2 Grease the top and bottom cylinder pins on the front and rear cylinders 3 Grease the fifth wheel using the two grease zerks located on to...

Page 25: ...ubs for cracks breaks or other damage D Grease slack adjusters SUSPENSION ASSEMBLIES A Inspect rubber bushings B Inspect mounting brackets for damage or broken parts C Make certain lock nuts on alignm...

Page 26: ...n for wear NOTE PERFORM THE ABOVE MAINTENANCE ON THE MINIMUM SCHEDULE WHETHER ON THE MILE OR CALENDAR BASIS WHICHEVER COMES FIRST CAUTION BE CERTAIN THE PRECEDING CHECKLIST INSPECTIONS HAVE BEEN PERFO...

Page 27: ...tor This allows the wheel s to begin rotating again thus avoiding lock up As soon as the wheels begin to rotate again the ECU reapplies pressure in the affected brake chambers to maximize braking effe...

Page 28: ...kid control unit that modulates signal pressure to prevent wheel lock up Relay valve to provide the high flow of air from reservoir to brake chambers required for good brake response Spring brake cont...

Page 29: ...Installation Service Manual for 2S 1M Systems PLC Select ABS 1M Page 12 Rev 6 0...

Page 30: ...l below 5 Attach hoses to appropriate brake chambers Use liquid thread sealant sparingly on all fittings Loctite PST565 or equivalent Note If frame mounted follow same procedure for valve orientation...

Page 31: ...R BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE WITH FMVSS 121 THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS ULTIMATE RESPONSIBILITY TO CERTIF...

Page 32: ...ow shows the correct power and speed sensor connections on the PLC Select 1M ECU Electronic Control Unit Page 19 Rev 6 0 ABS Power Cord Sensor S1A Curb Side Red Channel Sensor S1B Road Side Red Channe...

Page 33: ...trailer at the rear LED ABS warning lamp is acceptable Apply dielectric grease to all electrical connections 7 Way Wiring SAEJ560 Distance of ABS Light from Red rear clearance side marker light is 5...

Page 34: ...mp should flash 1 time The lamp will remain on after the wheel is stopped until the next wheel is rotated Rotate the road side wheel the ABS lamp should flash 2 times L55031W US 9 09 WEB ONLY Haldex L...

Page 35: ...g on the trailer Haldex does not require the disconnection of any ABS wire harnesses when welding on the trailer due to the fact that the ECU circuits have been specially designed to protect against t...

Page 36: ...onnections in your air lines be careful not to allow pieces of the sealer to enter the air system They can clog passages into the valves Keep the air system tight The air system cannot be charged prop...

Page 37: ...ustment CHECK BRAKE OPERATION Before entering traffic check the operation of the trailer brakes to be sure they are in good working order Try foot pedal emergency dash control valve push pull or flip...

Page 38: ...that has less than 2 32 tread depth TIRE LOADS Do not overload the trailer tires Overloading tires creates a dangerous unsafe condition that should be avoided The total load per tire must not exceed t...

Page 39: ...contact of wheels and hub Tighten nuts fully using the same alternate sequence Be sure to tighten wheel nuts only to the torque level recommended below and to maintain them at that level through plann...

Page 40: ...missing or damaged nuts or clamps f Bent or stripped studs g Damaged or missing rim drive plates h Mismatched rim parts 2 Pull damaged rims or wheels CAUTION Excessively corroded or cracked rims or ri...

Page 41: ...on the hub cap CAUTION Too much oil can damage the wheel bearings Use a gear type oil SAE 140 if temperature is above freezing SAE 90 if temperature is below freezing or a multipurpose oil with an SAE...

Page 42: ...tains a constant trailer height by pressurizing or exhausting air in the air springs as needed to support the load being carried You must build up and maintain your trailer s air pressure higher than...

Page 43: ...43 Suspension Torque Specifications...

Page 44: ...ler wiring Lights burn dim A Loose dirty or corroded terminals A Clean and tighten terminals or flicker B Poor or loose ground B Clean and tighten terminals on short ground cable in back if receptacle...

Page 45: ...ce axle C Loose nuts holding shackle box C Tighten or replace shackle box or shackle box liners WHEELS HUBS BEARINGS AND TIRES Malfunction Probable Cause Corrective Action Noise A Brake shoes drag on...

Page 46: ...turn spring D Bent axle spindle D Replace axle Brakes erratic or A Improper lubricant or grease inside A Clean and lubricate unequal brake drum or outside of wheel B Loose hub cap B Tighten hub cap C...

Page 47: ...aks Replace units that are found defective F Low air pressure F Check air pressure gauge on towing vehicle Pressure must not be below 80 PSI G Defective relay emergency valve G Replace defective valve...

Page 48: ...ect brake lining for sheared or worn rivets or bolts Replace defective brake shoe assembly C Loose or worn wheel bearings C Adjust wheel bearings If adjustment of wheel bearings does not correct the c...

Page 49: ...leakage persists replace defective connectors or airlines C Leakage at service or emergency line C Couplings are improperly connected couplings or packing ring gasket in hose coupling is defective Co...

Page 50: ...50 SS 102 4LS Tandem Leaf Spring Converter Dolly...

Page 51: ...l Tire Options 8 AAM8036 11R22 5 ON WHITE STEEL WHEELS 8 AAM8033 11R24 5 ON WHITE STEEL WHEELS 8 AAM8037 11R24 5 ON MACHINE FINISHED ALUMINUM WHEELS 8 AAM8008 11R22 5 ON MACHINE FINISHED ALUMINUM WHEE...

Page 52: ...CE PLATE LAMP CLEAR 12 VOLT 39 1 AP4121 LICENCE PLATE LAMP MOUNTING BRACKET GREY 44 1 AP4281 DECAL WARNING WHEEL NUT TORQUE 45 1 AP4292 DECAL HUTCH SUSPENSION TORQUE ORANGE BLACK 46 1 AP4301 ABS LIGHT...

Page 53: ...Y PREMIER 7A4 2 AP4334 HINGE MOUNT BRACKET PREMIER 441 7A5 4 AP4336 HEX CAP SCREW 1 2 20 X 4 GRADE 8 7A6 4 AP4337 NUT LOCK NYLON INSERT 1 2 20 7A7 4 AP3572 SPRING 3 LEAF 354 7A8 1 AP3642 FIFTH WHEEL H...

Page 54: ...K 3 8 MP 3 8 FP HALDEX N 13526 AG 54 1 AP4350 VALVE CHECK 1 2 MP 1 2 FP HALDEX N 13526 AJ 55 1 AP4355 VALVE ABS 1 2 NPT HALDEX N9001AD DOLLY 57 2 AP4399 COUPLING HEX REDUCER 1 2 FP 3 8 FP BRASS 58 2 A...

Page 55: ...y Item No Description 17 2 AP3537 NYLON TUBING RED 1 2 18 2 AP3537 NYLON TUBING RED 1 2 21 3 AP3635 NYLON TUBING BLUE 1 2 31 3 AP3745 HOSE 3 8 AIR BRAKE X 20 3 8 MP 3 8 MPX 43 2 AP4207 HOSE 3 8 AIR BR...

Page 56: ...56 Converter Dolly Tongue 33 1 2 Assembled...

Page 57: ...ING RUBBER PREMIER 448 5G 1 AP4335 HINGE SWIVEL PREMIER 424 R 5H 2 AP4338 HINGE ADJUSTMENT SHOE PREMIER 445 5I 1 AP4339 HINGE SWIVEL PREMIER 424 L 5J 4 BP3125 HEX CAP SCREW 1 2 13 X 1 GRADE 5 PLATED 5...

Page 58: ...58 Converter Dolly Tongue 33 1 2 Assembled...

Page 59: ...AIR 8 1 2 MP RED BLUE 19 2 AP4416 WIRE COILED 12 HD 1 10 6 12 BLACK 125CE 20 2 AP4463 SAFETY CABLE 5 8 X 72 DOUBLE LOOP 21 1 AP4469 HOSE 3 8 AIR BRAKE X 34 3 8 MP 3 8 MPX 22 2 AP4476 SPRING EXTENSION...

Page 60: ...60 Converter Dolly Tongue 78 Assembled...

Page 61: ...G 1 AP4335 HINGE SWIVEL PREMIER 424 R 5H 2 AP4338 HINGE ADJUSTMENT SHOE PREMIER 445 5I 1 AP4339 HINGE SWIVEL PREMIER 424 L 5J 4 BP3125 HEX CAP SCREW 1 2 13 X 1 GRADE 5 PLATED 5K 4 BP3216 SNAP RING 2 E...

Page 62: ...62 Converter Dolly Tongue 78 Assembled...

Page 63: ...EMIER 800P 15 620 688 24A 4 BP3006 HEX CAP SCREW 3 8 16 X 1 GRADE 5 PLATED 24B 4 BP3015 WASHER FLAT 3 8 PLATED 24C 4 BP3612 NUT HEX LOCK 3 8 16 TOP LOCK 25 2 AP4464 SAFETY CABLE 5 8 X 109 DOUBLE LOOP...

Page 64: ...64 Converter Dolly Tongue 108 Assembled...

Page 65: ...NT SHOE PREMIER 445 5H 1 AP4339 HINGE SWIVEL PREMIER 424 L 5I 4 BP3125 HEX CAP SCREW 1 2 13 X 1 GRADE 5 PLATED 5J 4 BP3216 SNAP RING 2 EXTERNAL 5K 1 AP4330 FRONT END ASSEMBLY PREMIER 340S 5L 1 AP4342...

Page 66: ...66 Converter Dolly Tongue 108 Assembled...

Page 67: ...CAP SCREW 3 8 16 X 1 GRADE 5 PLATED 23B 4 BP3015 WASHER FLAT 3 8 PLATED 23C 4 BP3612 NUT HEX LOCK 3 8 16 TOP LOCK 24 2 AP4467 SAFETY CABLE 5 8 X 139 DOUBLE LOOP 25 2 AP4468 HOSE 3 8 AIR BRAKE X 72 3 8...

Page 68: ...68 Converter Dolly Tongue 120 Assembled...

Page 69: ...NT SHOE PREMIER 445 5H 1 AP4339 HINGE SWIVEL PREMIER 424 L 5I 4 BP3125 HEX CAP SCREW 1 2 13 X 1 GRADE 5 PLATED 5J 4 BP3216 SNAP RING 2 EXTERNAL 5K 1 AP4330 FRONT END ASSEMBLY PREMIER 340S 5L 1 AP4342...

Page 70: ...70 Converter Dolly Tongue 120 Assembled 4 40 4 40...

Page 71: ...3006 HEX CAP SCREW 3 8 16 X 1 GRADE 5 PLATED 22B 4 BP3015 WASHER FLAT 3 8 PLATED 22C 4 BP3612 NUT HEX LOCK 3 8 16 TOP LOCK 23 2 AP4465 SAFETY CABLE 5 8 X 151 DOUBLE LOOP 24 1 AP4469 HOSE 3 8 AIR BRAKE...

Page 72: ...72 Converter Dolly Tongue 133 Assembled...

Page 73: ...NT SHOE PREMIER 445 5H 1 AP4339 HINGE SWIVEL PREMIER 424 L 5I 4 BP3125 HEX CAP SCREW 1 2 13 X 1 GRADE 5 PLATED 5J 4 BP3216 SNAP RING 2 EXTERNAL 5K 1 AP4330 FRONT END ASSEMBLY PREMIER 340S 5L 1 AP4342...

Page 74: ...74 Converter Dolly Tongue 133 Assembled 4 40 4 40...

Page 75: ...16 X 1 GRADE 5 PLATED 22B 4 BP3015 WASHER FLAT 3 8 PLATED 22C 4 BP3612 NUT HEX LOCK 3 8 16 TOP LOCK 23 2 AP4466 SAFETY CABLE 5 8 X 164 DOUBLE LOOP 24 1 AP4469 HOSE 3 8 AIR BRAKE X 34 3 8 MP 3 8 MPX 25...

Page 76: ...P 4180 1 ABS Kit PLC Select 1 AP3515 1 Light kit Warning 1 SN154FC 2 AP3528 1 MOD 1 FF ABS SB PRTY 3 4 NPT Includes Decals 3 AP3754 2 ABS sensor ext cord 1 meter 1 3 Decal 1 Haldex Midland 816 891 247...

Page 77: ...CAST REAR HANGER ROAD SIDE 16292 02 6 3 AP3965 ADJUSTABLE TORQUE ROD 19 1 4 16398 04 7 6 AP3967 TOP PALTE 7029 00 8 6 AP3968 SPRING SEAT 3 4 HEIGHT 9 6 AP3969 BOTTOM PLATE 10 3 AP3970 RIGID TORQUE RO...

Page 78: ...78 Hutch Single Point Suspension Parts...

Page 79: ...79 7700 9700 4 Spring Series Maintenance Procedures...

Page 80: ...80 7700 9700 4 Spring Series Maintenance Procedures...

Page 81: ...81 7700 9700 4 Spring Series Maintenance Procedures...

Page 82: ...82 7700 9700 4 Spring Series Maintenance Procedures...

Page 83: ...83 7700 9700 4 Spring Series Maintenance Procedures...

Page 84: ...Hub pilot non ABS cast drum steel hub 25 000 2 AP 3772 1 Hub pilot ABS cast drum steel hub 25 000 3 AP 4179 4 Brake spring canister 30 30 Arvin Meritor 800 535 5560 TQ4670QH5106 25 000 lb Non ABS TQ4...

Page 85: ...85 Hub Pilot Axles...

Page 86: ...86 Hub Pilot Axles...

Page 87: ...87 Hub Pilot Axles...

Page 88: ...88 Hub Pilot Axles...

Page 89: ...89 Hub Pilot Axles...

Page 90: ...90 Hub Pilot Axles...

Page 91: ...91 Hub Pilot Axles...

Page 92: ...92 Hub Pilot Axles...

Page 93: ...93 Hub Pilot Axles...

Page 94: ...94 Hub Pilot Axles...

Page 95: ...95 Hub Pilot Axles...

Page 96: ...96 Hub Pilot Axles...

Page 97: ...97 Hub Pilot Axles...

Page 98: ...98 Hub Pilot Axles...

Page 99: ...99 Hub Pilot Axles...

Page 100: ...100 Hub Pilot Axles...

Page 101: ...101 Hub Pilot Axles...

Page 102: ...102 Hub Pilot Axles...

Page 103: ...103 Hub Pilot Axles...

Page 104: ...104 Hub Pilot Axles...

Reviews:

No comments