User manual for tata prima 4928 car carrier application

Prepared by: RAMAN DHIMAN For any queries pl contact: [email protected] Strictly for Academic Purpose only. Not for any commercial use.

18.75 m Car Carrier Trailer on PRIMA 4028.S User Manual Guide


Contents

1) Introduction

2) Upper Deck Positions 2.1) Front Deck 2.2) Middle Deck 2.3) Rear Deck

3) Controls and Equipments 3.1) Hydraulic valve 3.1.1) Valve 1: To move upper deck & rear door 3.1.2) Valve 2: To move lower deck for Nano loading 3.2) Deck Locking arrangement 3.3) ABS: KB 4TA – G2 3.3.1) Park and Shunt Valve – AE 4311 3.3.2) Trailer ABS module 3.3.2.1) Electrical connections for 24 V trailer anti lock system 3.3.2.2) Pneumatic connections for 24 V trailer anti lock system 3.3.2.3) ISO 7638 connections 3.3.2.4) ABS warning lamp indication & blink code details 3.3.2.5) Load sensing valve 3.3.3) Load sensing valve 3.3.4) ABS warning lamp & ABS Connector – ISO 7683 3.4) 24 Volt Power Pack 3.4.1) Portable Button switch 3.4.2) Connections of Cable 1 – Red Colour


3.5) Brake Chambers & air tanks 3.6) Lashing arrangement 4) Car Carrier Trailer integration with PRIMA 4028.S 4.1) Decoupled Tractor trailer 4.2) Coupled Tractor trailer 4.3) King pin positions – coupled & decoupled 4.4) Procedure for coupling and decoupling 4.5) To connect Car Carrier & Prime Mover 4.6) To disconnect Car Carrier & Prime mover 4.7) Location of Fuse Box / Supply line coupling / 7 Pin connector / King Pin / Light Switch

5) Loading Configuration 5.1) Nano loading 5.2) Indica Vista / Indica loading 5.3) Sumo / Scorpio / Safari loading

6) Features

6.1) Exteriors 6.1.1) Right hand side view 6.1.2) Left hand side view 6.2) Interiors 6.2.1) Extra deck in the lower platform, and Anti skid perforated floor 6.2.2) Internal lights 6.2.3) Side & front cushioning 6.2.4) Service cover on rear axles


6.2.5) Three partition upper deck 6.2.6) Hydraulically operated tail gate. 6.2.7) Nylon pneumatic hose (as per DIN 73378) with 230 Voss connectors

7) Instructions 7.1) Instructions before operating the Power Pack 7.2) Upper deck operating instructions - Locking & Unlocking 7.3) Rear door operating instruction 7.4) Hydraulic operating Instruction 7.5) General

8) Service duration

9) Additional Information

9.1) Technical Specifications 9.2) Loading scenario for other than TATA vehicles 9.2.1) Alto 9.2.2) Swift D’zire 9.2.3) Indigo 9.2.4) Innova 9.2.5) Indigo Manza 9.2.6) Swift 9.2.7) Wagon R


1) Introduction: We are pleased to inform you about the introduction of Car Carrier Trailer on Prima 4928.S. Prima 4928.S is a Tractor - Trailer for long distance transportation with speed and reliability. PRIMA range of trucks is having following salient features:

• CRDI ISBe engine. • 9 speed gear box. • Hub reduction rear tandem axle. • Rear bogie suspension • World class cabin with HVAC, GPS. • Remote Keyless Entry with Central Door Locking. • New Generation Technology (NGT) Brakes

The Car Carrier Trailer has been provide with standardized Twin Axle, 8 leaf suspension, Twin 11R 20 Tyres, and ABS. To ensure the better accessibility and to provide quick and satisfying service while repairing and maintenance, proper service cutouts and well designed inspection windows are provided at proper locations. At the end, we say that this Car Carrier is meticulously designed to take care of vehicle transportation needs. Note:

• The pictures shown in this manual are for illustration purpose only.


2) Upper Deck Positions: There are three partitions in the top deck.

2.1) Front Deck: With the help of Lead Screw, the front Upper Deck can be adjusted to take positions 1, 2, and 3.

S.No. Vehicle Type Recommended Front Deck Position

1 Nano 3 2 Indica Vista 3 3 Indica 3 4 Scorpio 1 5 Alto 3 6 Wagon R 3 7 Swift / i-10 / i-20 3 8 Safari 1 9 Indigo Manza 3

10 Indigo 3 11 Swift D’zire 3 12 Innova 2

Operating Steps:

1) Remove the Locking pin 2) Move the deck Up or Down with the help of

Adjustable nut 3) After deck movement lock the deck

Caution:

1) Don’t forget to lock the deck 2) Movement of the deck should be as per chart attached

Top Position

Middle Position

Lead Screw

Locking Pin

Adjustable Nut

Up

Down

Figure 1

Bottom Position


2.2) Middle Deck – Front End: With the help of Lead Screw, the front end of the Middle Upper Deck can be adjusted to take positions A, B, and C

S.No. Vehicle Type Recommended middle

Deck Position 1 Nano C 2 Indica Vista B 3 Indica B 4 Scorpio A 5 Alto C 6 Wagon R B 7 Swift / i-10 / i-20 B 8 Safari A 9 Indigo Manza B

10 Indigo B 11 Swift D’zire B 12 Innova C

Operating Steps:



Caution:


Top Position for front end of Middle Upper Deck Middle Position for front end of Middle Upper Deck

Bottom Position for front end of Middle Upper Deck

Locking Pin

Lead Screw

Adjustable Nut

Up

Down

Figure 2


2.3) Rearmost Deck – Front End: With the help of Lead Screw, the front end of the Rearmost Upper Deck can be adjusted to take positions X, and Y.

S.No. Vehicle Type Recommended Rear

Deck Position 1 Nano Y 2 Indica Vista Y 3 Indica Y 4 Scorpio X 5 Alto Y 6 Wagon R Y 7 Swift / i-10 / i-20 Y 8 Safari X 9 Indigo Manza Y

10 Indigo Y 11 Swift D’zire Y 12 Innova X

Operating Steps:



Caution:


Up

Down

Top Position for front end of Rearmost upper deck

Bottom Position for front end of Rearmost upper deck

Locking Pin

Lead Screw

Adjustable Nut

Figure 3


3) Control & Equipments: 3.1) Hydraulic Valve Positions: There are 2 valves 3.1.1) Valve 1: To move Upper Deck & Rear Door 3.1.2) Valve 2: To move lower deck for Nano Loading

3.1.1) Operating Steps for Valve 1: To move Upper Deck & Rear Door: a) Lever 1: For upper deck movement. In order lower the Upper Deck move the lever backwards, and to raise

the Upper Deck Up move the lever forward. b) Lever 2: Rear Door movement: In order to lower the rear door move the lever backwards, and to raise the

rear door move the lever forward.

For Upper Deck movement For Rear Door movement

Up

Down

For Upper Deck movement For Rear Door movement

Down

Up

Figure 4


3.1.2) Operating Steps for Valve 2: To move lower deck for Nano Loading : In order to raise the lower deck, for Nano loading move the lever in forward direction, and to lower it move the lever backwards.

Caution: Before lifting the deck gap between the first & second Nano: on lower deck should be 420 mm

Forward: to move the Lower Deck Up

Backward: to move the Lower Deck Down

Figure 5


Position before lifting the Lower Deck for Nano Loading: Position after lifting the Lower Deck for Nano Loading:

420 mm

Figure 6

Figure 7


3.2) Deck locking arrangement: There are 8nos of locks in the vehicle. (06 nos. square bar and 02 nos. round pin type)

Operating Steps:

1) Remove the Locking Pin 2) Take the manual lock out 3) Adjust the movement of deck as required 4) Re-insert the manual lock & locking pin.

Caution: While loading cars into the vehicle, manual locking should be done from the rear lock to the front lock in order to avoid any accidents, and while unloading cars from the vehicle disengage the manual locking from front end to rear end.

Open

Close

Manual Lock

Figure 8

Locking Pin

Ram resting pins for rearmost upper deck

Ram resting pin for lower deck

Figure 9

Figure 10


3.3) ABS KB4TA – G2: The Knorr – Bremse KB4TA-G2 module is an integrated trailer ABS controller and modulator for air-braked heavy duty trailers, semi-trailers and full trailers. The module acts as two relay valves during normal braking, but during ABS events, it will intervene to help improve stability. All modules include an Electronic Control Unit (ECU) and two Modulator Relay Valves (MRV). 3.3.1) Park & Shunt Valve AE4311: Features: 3.5.1) Priority to service braking system during charging 3.5.2) Spring brakes held off during energy consumption test 3.5.3) Spring brakes fully applied when reservoir pressure < 3.0 bar

Park Valve Connected to Spring Brake Actuators (SBA) of trailer

Shunt Valve Connected to Supply Line

Figure 11


3.3.2) Trailer ABS Module: 3.3.2.1) Electrical Connections for 24 Volt Trailer Anti Lock System: The Knorr – Bremse KB4TA-G2 module ECU connectors use a 12-pin Deutsch DT series connector for ISO 7638 power supply, diagnostics and auxiliary I/Os like ISO 1185 stop light power supply.

3.3.2.2) Pneumatic Connections for 24 Volt Trailer Anti Lock System:

Sensor for right hand side wheel Sensor for Left hand side wheel

Auxiliary sensor – Not used in Car Carrier

Auxiliary sensor – Not used in Car Carrier

To Right hand side Brake Chamber

To Spring Brake Actuator

Control - Red

To Left hand side Brake Chamber

To Spring Brake Actuator

Brake - Yellow

Figure 12


3.3.2.3) ISO 7638 Connection: Pin 1: Valve Supply Pin 2: Ignition Pin 3: Valve – Ground Pin 4: Ignition - / Warning Lamp Ground Pin 5: Warning Lamp Pin 6: Controlled Area Network CAN Low Pin 7: Controlled Area Network CAN Hi

3.3.2.4) ABS Warning Lamp Indication: In Case of any problem with the ABS the warning lamp will glow. In order to detect the error press the diagnostic switch 3 times, then warning lamp will first glow say for “x” times then stop and then again for “y” times and after that it will remain continuously on. Note down the combination “xy” and refer to the blink code chart below, for remedial action. In case you do not find the code in the chart, please refer to the nearest TATA Dealership.

ABS Warning Lamp

Male ABS Connector

Diagnostic Switch

Figure 14

Female Connector on PRIMA To be connected to Male ABS connector on Car Carrier Trailer

Figure 13


Blink Code Chart for KB4TA-G2 module: 1st Code Blink 2nd Code Blink Information on action required Code Location Code Description

1 All 1 No Faults System fully operational – no faults detected

2 3

Sensor SL Sensor SR

1 Wheel speed sensor air gap too big

Call Knorr Bremse representative 2 Loss of wheel speed sensor signal 3 Noisy wheel speed sensor signal 4 Short or open circuit wheel speed sensor 5 Tyre size differential out of range Verify correct tyre size, proper tyre inflation 6 Wheel speed sensor configuration error Call Knorr Bremse representative

6 Power supply

1 Voltage too high Check battery voltage supply and alternator 2 Voltage too low Check battery voltage supply and alternator

3 Excessive resistance ISO7638 pin 1 Check for high resistance (corrosion, wire /connector damage or improper termination of te power line)

7 8 9

Modulator M22 Modulator M21 AUXI01/Modulator

2 Exhaust solenoid shorted or open circuit Call Knorr Bremse representative 3 ABS valve installation error

4 Valve configuration error

10 Common

1 Internal short to ground

Check for damaged or corroded connectors . Check for damaged wiring. After connections or if no issues found, then clear trouble codes. If problem returns, call Knorr Bremse

2 AUX101 or modulator 2 short to ground

Call Knorr Bremse representative 3 ABS modulator dynamic error –all valves 4 Excessive ABS activity 5 AUX101 or modulator2 short to battery

11 ECU 1 Internal error

Check for damaged or corroded connectors . Check for damaged wiring. After connections or if no issues found, then clear trouble codes. If problem returns, call Knorr Bremse

2 Configuration error Call Knorr Bremse representative

12 AUXIO2 1 Shorted or open circuit Check for damaged or corroded wiring or connectors

13 AUXIO2 1 Shorted or open circuit Check for damaged or corroded wiring or connectors

14 System 2 Service Interval exceeded


3.3.2.5) Load Sensing Valve: The load sensing valve is used to adjust the applied service brake pressure in relation to the load imposed on the vehicle’s axles. The mechanical suspension load sensing valve uses the movement between the vehicle’s chassis and axles to sense the load imposed on the axles. The valve is installed on the chassis and a linkage is required to connect the control arm of the valve to the axle(s). Any movement of the chassis changes the position of the valve’s control arm which, in turn, alters the ratio of input pressure to output pressure.

Load Sensing Valve

Figure 15 Figure 16


3.4) 24 Volt DC Power Pack: Pl refer to the steps below to operate the Power Pack Operating Steps: Step 1: Connect one end of the Cable 1 – red color to the positive terminal of battery, and other end to connector C Step 2: Operation of Valve 2 (Fig. 5): Connect female connector F to Male connector B Step 3: Press the red button to move the deck up & simultaneously operate the lever of Valve 1. There is no need to press the red button while moving the deck down Step 4: Operation of Valve 1 (Fig. 4): Connect female connector F to Male connector Step 5: Press the red button to move the deck up & simultaneously operate the levers of Valve 2. There is no need to press the red button while moving the deck down

Battery

B A

F

Button Switch

Male Connector at Valve 2

Male Connector at Valve 1

Female connector for A & B

Power Pack

C

Cable 1 – Red Color Connector

Electric Motor

Cable 2 – Black Color

DC Electric Motor

Return Line

Pressure Line

Oil Tank 32 liters (Grade 68)

Figure 17


3.4.1) Portable Button Switch: Button switch has been provided in order to operate hydraulics Operating the Button Switch: There is 1 no. of switch that is available with every vehicle, and it has to be operated in parallel with the valve movement to lift the hydraulic cylinder, but it is not required at the time of lowering of decks Caution: In order to move the deck Up / Down operate the switch & hydraulic lever simultaneously

Figure 18

Portable Button Switch

Male Connector at the location of Valve 1 & Valve 2

Female Connector with Portable Button Switch

Figure 19

Male Connector at the location of Valve 1 & Valve 2

Female Connector with Portable Button Switch

Figure 20 Figure 21


3.4.2) Connections of Cable 1 – Red Colour: Before operating the hydraulics One end of Cable 1 should be connected to positive terminal of battery & other end to Power pack cable – Black colour

One end of cable 1 connected to Battery

One end of cable 1 connected to Power Pack Cable

Power Pack Cable end

24 Volt Battery

Figure 24

Figure 25

Figure 23

Figure 22


3.5) Brake Chamber & Air Tanks: Rearmost axle has been provided 2 nos. of T 30 / 30 Knorr – Bremse Spring Brake Actuators, having a provision for Parking, and the front axle has been provided with 2 nos. of T 30 Brake Chambers. There are 2 nos. of air tanks with the capacity of each one to be 50 liters.

T 30 / 30 Knorr – Bremse Spring Brake Actuator

T 30 Knorr – Bremse Brake Chamber

Figure 28

Figure 26 Automatic Slack Adjuster

Air Tanks: Capacity 50 liters each

Figure 27


3.6) Lashing Arrangement: Lashing arrangement varies from vehicle to vehicle or from manufacturer to manufacturer, but broadly two types of lashing arrangement is recommended. Option 1: Lashing belt around the tyre of the vehicle.

Option 2: Lashing around wish bone / rear or front axle / independent suspension:

Figure 31 Figure 30

Figure 29


4) Car Carrier Trailer Integration with the Prime Mover:

4.3) King Pin Positions Coupled & Decoupled:

4.1) Decoupled Tractor Trailer

4.2) Coupled Tractor Trailer


4.4) Procedure for Coupling & Decoupling:


4.5) To Connect Car Carrier & Prime Mover: Step 1: Secure the Car Carrier to prevent its rolling away Step 2: The fifth wheel coupling must be ready to engage; otherwise, open the fifth wheel coupling Step 3: Check the height of Car Carrier. The skid plate must ideally be at the same height as or not more than 50 mm lower than the coupling plate on the fifth wheel coupling Step 4: Drive the tractor unit under the Car Carrier Step 5: The locking mechanism will close automatically Step 6: Conduct an initial driving test in a low gear Step 7: Check the locking mechanism Step 8: Connect the supply lines Step 9: Retrace the landing gear Step 10: Release the parking brake and remove the chocks. Caution: Check the locking mechanism status before starting any journey. 4.6) To Disconnect Car Carrier & Prime Mover: Step 1: Park the vehicle on flat firm ground Step 2: Secure the Car Carrier to prevent its rolling Step 4: Extend the landing gear Step 5: Disconnect the supply lines Step 6: Open the fifth wheel coupling Step 7: Drive the tractor unit out from under the Car Carrier Step 8: The fifth wheel coupling is automatically ready for engagement again.


4.7) Location of Fuse Box/ Supply Line coupling / 7 Pin Connector / King Pin / Light Switch

Fifth Wheel Coupling

Figure 33 Figure 34

Figure 11

Spare Wheel

Supply Line DIN ISO 1728

7 – Pin Connector ISO 1185

2” Bolted Kingpin IS 6763

Service Line DIN ISO 1728

Fuse Box

Light Switch ON/OFF

Figure 32


5) Loading Configurations 5.1) Nano Loading: Step 1: Open rear door - Move the lever 2 of Valve 1 in forward direction - Fig 4 Step 2: Take the rear ladder out of the rear door Step 3: Rearmost upper deck down: Move the lever 1 of Valve 1 in backward direction – Fig 4 Step 4: Set all the Upper decks in 3-B-Y position Step 5: Load the first Nano Step 6: Lift the front end of the middle upper deck to position C

Figure 35


Step 7: Load the remaining Nano in the upper deck. Step 8: Move the Upper Deck up – Move the Lever 1 of Valve 1 in the forward direction. Step 9: Load the first Nano in the lower deck Step 10: Maintain a Gap of 420 mm between first and second Nano in the lower deck Step 11: Raise the Lower deck up – Move the lever of Valve 2 in forward position – Fig 5 Step 12: Load rest of the 3 Nano in lower deck

Figure 36

Figure 37


5.2) Indica Vista / Indica Loading: Step 1: Open rear door - Move the lever 2 of Valve 1 in forward direction – Fig 4 Step 2: Take the rear ladder out of the rear door Step 3: Rearmost upper deck down: Move the lever 1 of Valve 1 in backward direction – Fig 4 Step 4: Set all the Upper decks in 3-B-Y position Step 5: Load the first Indica Vista / Indica Step 6: Load the remaining Indica Vista / Indica in the upper deck. Step 7: Move the Upper Deck up – Move the Lever 1 of Valve 1 in the forward direction – Fig 4 Step 8: Load the remaining 4 Indica Vista / Indica in the lower deck,

Figure 38

Figure 28

Figure 39


5.3) Sumo / Scorpio / Safari Loading: Step 1: Open rear door - Move the lever 2 of Valve 1 in forward direction – Fig 4 Step 2: Take the rear ladder out of the rear door Step 3: Rearmost upper deck down: Move the lever 1 of Valve 1 in backward direction – Fig 4 Step 4: Set all the Upper decks in 1-A- X position Step 5: Load the first Sumo / Scorpio / Safari in the upper deck Step 6: Lift the front end of the middle upper deck to position B Step 7: Lift the front end of the rearmost upper deck to position Y Step 8: Raise the Upper deck: Move the lever 1 of Valve 1 forward – Fig 4 Step 9: Load the 1st and 2nd Sumo / Scorpio / Safari in the lower deck Step 10: Lower the upper deck: Move lever 1 of Valve 1 backward Step 11: Load the remaining 2 Sumo / Scorpio / Safari to the upper deck.

Figure 40


Step 12: Raise the upper deck Step 13: Load Indica Vista / Indica / Alto to the rearmost of lower deck.

Figure 41

Figure 42


5) Features: 6.1) External Features: 6.1.1) Right Hand Side View:

Front Dome in order to accommodate 4 nos. of Indica on the top

Front End Outline Marker Lamp RH Top

Reflective Tape

Display Board – It can be rotated

Rear End Outline Marker Lamp

Side Marker Lamps

Front End Outline Marker Lamp - RH

Ladder – To adjust the position of display board

Rear End Outline Marker Lamp RH Top

Figure 43


6.1.2) Left Hand Side View:

Rear Window in order to operate Valve 1 (see Fig. 4)

Middle Window in order to operate Valve 2 (see Fig. 5)

Upper Inspection window

Display Board – LH It can be rotated

Ladder for inspection window

Ladder LH for Display Board

Front End Outline Marker Lamp LH Top

Side Marker Lamps

Figure 44


6.2) Internal Features: 6.2.1) Extra Deck in the lower platform, and anti skid perforated floor: With the additional deck in lower platform 10 nos. of Nano can be added

6.2.2) Internal Lights: 5 Watt internal lights have been provided in Upper deck and lower deck

5 Watt Internal Lamp

Figure 48 Figure 47

Additional Deck

Hydraulic Cylinder

Locking Pin

Perforated Floor Figure 46 Figure 45


6.2.3) Side & Front Cushioning: In order to prevent any kind of scratches while loading and unloading of the vehicle.

6.2.4) Service cover on rear axle: For easy accessibility of axle aggregates, ABS aggregates, Air Tanks, and Power pack service cover has been provided. When not in use it can be bolted in order to provide vibrations.

Service cover hinged at one end & bolted at the other

ABS Module

Trailer front

Rear Axle with T 30 Brake Chambers Figure 50

Internal Cushioning Figure 49


6.2.5) Three partition Upper Deck: The upper deck is in three parts.

6.2.6) Hydraulically operated Tail Gate: Both Up & Down movement of the tail gate is hydraulically controlled – Valve 1, Fig 4.

Tail Gate

Wipro Hydraulic Cylinder – Operated from Valve 1, Fig 4

Extendable ladder Figure 53 Figure 52

First Deck Second Deck Third Deck

Figure 51


6.2.7) Nylon Pneumatic Hoses with 230 Voss Connectors: Nylon Pneumatic hoses as per DIN 73378 with Voss 230 connectors has been provided.

Park and Shunt Valve

M 15 – Voss Connector

M 12 – Voss Connector

Nylon Hose As per DIN - 73378

Figure 55

Figure 54


7) Instructions:

7.1) Instructions before operating the Power Pack: Ø Check all connections are OK & not loose. Ø Crocodile clamp – Cable 1 (Red Colour) is properly connected at both ends. Ø The 7pin connector and socket are properly inserted.

7.2) Upper deck operating instructions - Locking & Unlocking: Ø To Unlock - Start removing the ram resting pins from the innermost deck to the outermost deck. Ø To Lock - Start locking the ram resting pins from the outermost deck to the innermost deck. Ø Please insure that while doing the operations no one is there in the danger range of upper deck.

7.3) Rear door operating instruction Ø Before opening the door, please ensure that the rear door locks- both inside & outside are unlocked. Ø During the operations of the rear door, no one should be there in the danger range of it.(rear door backside) Ø While loading cars, the slider ramp & the outside stand should be locked properly. Ø After loading, the slider ramp should be properly inserted and locked. Ø Outside stand should be properly locked before closing the door. Ø After closing the door, lock it from inside & outside.

7.4) Hydraulic operating Instruction Ø Please do not put any weight on Hydraulic pipe line Ø Check oil level in tank on regular basis. Ø At a time please operate single lever, do not operate both lever simultaneously. Ø Always operate the lever first and then start the power pack for safe working of Hydraulic.


7.5) General Ø Please do not load the vehicles on uneven surface as it is harmful for cylinders seal. Ø While operating Hydraulics, please check no one is in range of Rear door / Upper deck / Lower deck. Ø Always park cars in center of upper deck & lower floor. Ø Properly grease all pins and screw. (Once after trip). Ø Please check all Hydraulic fittings periodically (once after trip). Ø Always follow vehicle loading guidelines.


8) Servicing duration

PRIMA 4028S FREQUENCY

DA

ILY

40,0

00

80,0

00

1,20

,000

1,60

,000

2,00

,000

GeneralCheck if necessary tighten: Mounting of air tanks 80,000If abnormal wear found on tyre, perform wheel rotation.Check if necessary tighten: Air line clamps 80,000Chaeck brake rubber hoses/air pipes for damages/ leaks and replace if necessary.BRAKES

Dismantle pneumatic aggregates of brake system like air compressor, Dual brake valve. Air processing unit relay valve, TCV, palm coupling,LSV, exhaust brake, brake chamber, ASARemove brake drums, inspect brake linnings, brake drums etc. Rectify defects if any.Check condition of brake valves, exhaust flap in dual brake valve, nylon breather tube and clips of spring brake actuator. Replace if found damaged. 80,000Check mounting bolts of brake chambers, air tanks hydraulic pipes and tighten if necessary. 80,000Conduct brake system routine checks. 80,000overhaul foundation brakes.

Check brake torque plate mounting bolts and tighten if necessaryAXLES

Remove front hubs, dismantle and clean bearing and other components. Replace damaged/worn out parts. Repack with fresh wheel bearing grease, and refit.Adjust wheel hub bearing play. 40,000Check for wheel hubs play and for noise adjust if required. 40,000Change oil in rear axle including hubs, drain while hot, clean drain plug and breather. 80,000Check and tighten if necessary carrier and rear cover mounting nuts. Also tighten axle shaft cover mounting bolts, rear axle carrier mounting studs. 40,000

At every lining change

To be checked when leakage noise is observed.

Every 3,00,000 kms

At every lining change

Every 3,00,000 kms


HydraulicsCheck the oil level in Power Pack Tank

Electrical motor

SUSPENSIONCheck shock absorber & replace if necessary 80,000

OTHERS

ELECTRICALSCeck all sensors and connectors for cleanliness and secure fitment. After every WASH

Dismantle front and rear springs. Clean and inspect leaves. Check and replace eye bushes, if necessary. Apply graphite graese on leaves and reassemble. 80,000


9) Additional Information: 9.1) Technical Specifications:

Model 4028.SType 18.75 m Car Carrier TrailerIndica Vista loading 8Indica loading 8Nano loading 10

Chassis DetailsEngine Cummins ISBe

Clutch Single plate dry friction type,Outside dia. Of clutch lining 430

Transmission ZFWheel & Tyres 11 R X 20, 16 PRWheelbase,mm 3460Max. Width,mm 2500Front Overhang,mm 1465

Weighta) Max. Payload, Kg 20100b) Chassis Wt. Kg 7200c) Tare, Kg 12700d)GVW,Kg 40000

External Dimensions:Length 16240Width 2600Height 4750

Lower Side Panel : 1.25 mm ( 18 gauge ) Upper Side Panel : 1.00 mm ( 20 gauge )Grade: DD 1079 SS 4013A

Hydraulically operated Door Frame1 Stage Hydraulic Cylinder -Open length: 1996 mm, Closed length : 1146 mm2 No. Wipro make

Track HR 2.5 mm Perforated (12 gauge),Material Grade: Fe 410Body

Specification Sheet for 18.75 m Car Carrier Trailer on PRIMA 4028.S


Suspension:

Tandem suspension with YTE 75/90, 8 Leaf Springwith Bronze equalizer bush & rubber torque arm bush

IS 1135, IS 3431BS 1149, BS 970En 45

Tyres 11 R X 20 Rib Tyre, 16 PR

Wheel Rim 8 X 20, 10 Hole, 335 PCD, Offset 172, 8 nos.

Axle 12 Ton Dummy axleNo. 2Make York NGT AxleTrack, mm 1850Beam Section, ( WXH) 127 mm round, Seamless round tubePlate thickness 19Brake Assembly Brakes India Ltd.Hub Lubrication GreaseBrakes - S cam type 410 X 220Drum/Wheel PCD 335Wheel Rim Fixing Dia. 280.8Wheel Bolts M 22 X 2.5 ( 10 nos.)Rated Load 12 tonWeight of axle, Kg 405Beam wt. per metre 50.58Slack Adjuster AutoBrake Dia. 410

Brakes: At 8.0 Bar

Service Brakes S-Cam brake system, 7 port Relay Emergency Valve

Lining area 410 X 220Parking Brake YesType Spring typeEngine Exhaust Brake NAService Brake Actuators /Brake Chambers

Brake Chambers: T 30 - 2 No.Service Brake Actuators: T 30/30 - 2 No.


Brake ActuationSupply Pressure: 8 bar, Knorr Bremse KB4TA-G2 Trailer ABS(2S-2M) Front Axle, with Park shunt & emergency valve, SBA 30/30 in rear axle, T30 Brake Chambers in the front axle,Load sensing valve on the front axle, Nylon Brake pipe & Voss 230 quick connectors

Parking Brake Pneumatic Parking brake on rear axle

ABS Type 2S- 2M, Make: Knorr Bremse,Present on the front axle

Air Tank 2 No., 50 litres each.

Brake Coupling 2 Palm Coupling, Top Head Seal ( Red/Yellow M22 X 1.5)

Landing Legs: Manual with static capacity 40 T

King Pin2" Bolted, 8 Bolts M12, Max rating 102 kNIS 6763Material: En 19

Spare wheel Carrier 1 No.

Electrical:

24 Volt DC elecrical system, 7 Pin Elecerical Connector- ISO 1185 ( Ground, Trailer Market light, Trailer Left Turn Light, Trailer Stop Light, Trailer right turn light, Trailer taillight, trailer power)

Parking, brake , indicator lights . Electrical system conforming to Indian regulations. Rear marker and side reflectors.

Hydraulic System

For lower deck: CL ( Closed Length)-1146,OL ( Open Length)-1996 (55x2x36), 2 No. Wipro make, For upper deck: CL ( Closed Length)- 870,OL ( Open Length)-1200 , 2 No.,Wipro make, 24 volt D. C. Power Pack, Dantal Make.


9.2) Loading scenario of other Vehicles: 9.2.1) Alto 9.2.2) Swift D’zire:

Figure 57

Figure 56


9.2.3) Indigo: 9.2.4) Innova:

Figure 59

Figure 58


9.2.5) Indigo Manza: 9.2.6) Swift

Figure 61

Figure 60


9.2.7) Wagon R:

Figure 62

Automotive

User manual for tata prima 4928 car carrier application