TECHNICAL PROCEDURE

For
Servicing of Lift Axle Suspension System
For Rigid Truck LPT 3118 &
LPT 3718 Pusher I Prima 3123.T &Prima 3723.T

Information provided in this bulletin Is accurate as on the date of publishing .Changes would have bean
made in the product after the date of this publication. Please get in touch with us for any updates

TATA AUTOCOMP HENDRICKSON SUSPENSIONS PVT LTD

Gat No. 431/1, Medankarwadi, Chakan -Alandi Road, Off. Pune - Nashik Highway,
Near Hotel Gandharwa, PUNE -410 501 I Tel:+91 2135 670670 I Email: service@tacohendrickson.com
 •TwJTATA (HJ I ;i . I I : l 1-l .._:- I

Technical Procedure
Subject : Service Instructions
LIT No. : Pusher Axle Suspension
Release : 20161 Revision : O

SR. NO. DESCRIPTION PAGE

A Introduction ......................................... 01

B Recommended Maintenance schedule .................... 03

C Dos and Don'ts for driver/operator........................ 04

D General & Special tools required ......................... 06

E Main Air Spring Service Procedure ....................... 08

F Lift Air Spring Service Procedure ......................... 10

G Rebound Strap Service Procedure ....................... 12

H Wear Pad Service Procedure ........................... 14

Bushing outer Rubber Service Procedure ................. 20

J Steering Stabilizer Service Procedure ..................... 26

K Troubleshooting Guide................................. 29

L List of Serviceable Child Parts ........................... 30

M GAP Measurement between Axle Seat &

External Bump stop ................................... 30

N Part No. Cross reference & Torque Values ................. 31

i) Torque Values 3118/3718 Pusher
ii) Torque Values 3123.T/3723.T Prima
•T• TATA [HJllEIDRICKSOrt PARALIFT SUSPENSION s
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A. Introduction
This publication is to acquaint and assist maintenance personnel in preventive maintenance and
rebuild of the PARALIFTsuspension system.
-
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THSL reserves the right to make changes and improvements to its products and manuals at any time.
Contact THSL Tech Services at +91 2135 670 670 or service@tacohendrickson.com for information
on the latest version of this manual.

NOTE Use only genuine THSL parts for servicing this suspension system. Most THSL parts can be identified
by the Hendrickson trademark.

IMPORTANT SAFETY NOTICE

Proper maintenance, service and repair is important to the reliable operation of the suspension. The
procedures recommended by THSL and described in this technical publication are methods of
performing such maintenance, service and repair.
The warnings and cautions should be read carefully to help prevent personal injury and to assure that
proper methods are used. Improper servicing may damage the vehicle, cause personal injury, render
it unsafe in operation, or void manufacturer's warranty.
Failure to follow the safety precautions in this manual can result in personal injury and/or property
damage. Carefully read, understand and follow all safety related information within this publication
and on all decals.

EXPLANATION OF SIGNAL WORDS

Hazard "Signal Words" (Danger-Warning-Caution) appear in various locations throughout this
publication. Information accented by one ofthese signal words must be observed to help minimize the
risk of personal injury to service personnel, or possibility of improper service methods which may
damage the vehicle or render it unsafe. Additional Notes or Service Hints are utilized to emphasize
areas of procedural importance and provide suggestions for ease of repair. The following definitions
indicate the use of these signal words as they appear throughout the publication.

A DANGER
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR
DEATH.

A WARNING
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.

A CAUTION
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO
MACHINE OR MINOR PERSONAL INJURY.

NOTE An operating procedure, practice condition, etc. which is essential to emphasize.

SERVICE HINT Ahelpful suggestion which will make the servicing being performed a little easier and/or faster.

WARNINGS AND CAUTIONS

There are various warnings and cautions that should be read carefully to minimize the risk of personal
injury and to assure that proper methods are used. Improper servicing may damage the vehicle or
render it unsafe in operation.

1
PARALIFT SUSPENSION •T•TATA H1 : I ;..ii I 'l I"' .._:· 1

A WARNING LOAD CAPACITY

THSL REMINDS USERS TO ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE
SUSPENSIONS. ADD·ON AXLE ATTACHMENTS AND OTHER LOAD TRANSFERRING
DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE THE RATED AND APPROVED
CAPACITIES WHICH COULD RESULT IN FAILURE AND LOSS OF VEHICLE CONTROL,
POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

A WARNING
MODIFYING COMPONENTS
DO NOT MODIFY OR REWORK PARTS. DO NOT USE SUBSTITUTE PARTS OF THE
SUSPENSION. USE OF AMODIFIED OR REPLACEMENT PARTS NOTAUTHORIZED BYTHSL
MAY NOT MEET THSLSPECIFICATIONS, AND CAN RESULT IN FAILURE OF THE PART, LOSS
OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE. USE
ONLY THSL AUTHORIZED REPLACEMENT PARTS DO NOT MODIFY PARTS WITHOUT
AUTHORIZATION FROM THSL.

A WARNING
TORCH /WELDING
DO NOT USE A CUTTING TORCH TO REMOVE ANY ATTACHING FASTENERS. THE USE OF
HEAT ON SUSPENSION COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF
THESE PARTS. A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS OF
VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

A CAUTION
PROCEDURESANDTOOLS
A MECHANIC USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN
RECOMMENDED BY THSL MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY
NOR THE VEHICLE'S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL
SELECTED. INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS
PROVIDED ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO
EQUIPMENT INVOLVED.

A WARNING
PERSONNEL PROTECTIVE EQUIPMENT
ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL
PROTECTIVE EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN YOU PERFORM
VEHICLE MAINTENANCE, REPAIR OR SERVICE.

Know the system

Para lift Suspension •
Fig 1.1: Paralift Suspension System PH-3 Suitable for
LPT 3118 &LPT 3718 Pusher I Prima 3123.T & Prime 3723.T
Chassis long fReiiOUndl I Rebound I
mem~r snp
~

~-------------------/-------~~

I Main Air Spring I

Axle seat

I Stabilizer
I Z-section 11 Beam Assembly 1 Lift Air Spring I
1

2
•T• TATA [H]llEIDRICKSOrt PARALIFT SUSPENSION ~
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llMtllm Table 2.1

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ns
Parameter to be Activity
c
SI Component checked
Interval .!
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1 Main Main Air Spring Height During regular Refer TML Operator
::&:
Air T250 ± 25mm {in Lift Axle service interval Service Book for more 'C
Spring Deployed condition) details Cl)
'C
cCl)
E
Leakage Regularly Check for air leakage E
0
2 Lift Air u
Leakage Regularly Check for leakage
Spring &
3 Steering Leakage Regularly • Check for leakage I structural
Stabilizer damage
m
• Check wheel cut angles and
position of wheel cut stopper
as mentioned in TML
Vehicle Manual
4 Rebound Broken Regularly Replace it if found cut or
strap damaged
5 Wear Pad Damage I wear As required • Replace it, if found
damaged I worn out.
• Replace whenever adjacent
parts like bush being replaced

6 Beam Damage I wear Check whenever Replace if found damaged or

Bushes Beams are worn out
disassembled for
repair or service.
7 M27 Torque Value First service at Verify torque and if necessary
Fastener 40000 km and Re-torque by applying
the next every specified torque.
service interval *Refer Section N for
ofTruck Torque values
8 Pneumatic Functioning During regular a. In Fully Laden condition
System service interval (at specified GVW) lift axle
should be lowered
b. Lift axle should be lifted
automatically when the
reverse gear is engaged
c. Lift Axle should be lowered
automatically when the
ignition is switched off
9 External Gap measurement During regular *Refer Section - Mfor
Bump Stop service interval details
Note:
1. Stop &turn off the vehicle before servicing lift axle
2. Do avail the services of workshop authorized by OEM for servicing pneumatic circuits.
Component damage, loss of vehicle control might occur if there is any incorrect correction or
alteration.
3. Use only TATA /THSL Genuine parts for lift axle components/parts/sub-assemblies/Fastener

3
PARALIFT SUSPENSION •T•TATA rHJllElllllllCKIOI
C • DOs and DON'Ts for
driver I operator with lift
axle fitted vehicle.
Do's and Don't's Table 3.1
Sr. No. Do's and Dont's Photo

Ensure air supply to air spring is

disconnected while working on air
spring or related components.
1 Sudden release of high
A WARNING pressure air can lead to body
injuries.

While working on structural

components involving high
torques, ensure that all personnel
are at safe distance and torque
2 wrench grip is firm.

A WARNING
Torque wrench slippage could
cause fatal injury.

Allow sufficient clearance around

the air spring else, air spring would
weaken if metal parts continuously
3 rub with it.
A CAUTION Weak airspring would fail soon.

Use only THSL or TML supplied

components/parts/ subassemblies/
fasteners for replacements.
4 Substandard fasteners cannot retain
torque for long and work loose.
A CAUTION Loose bolts make holes oblong and
lead to consequentialdamages

Use only THSL or TML supplied

components I parts

A CAUTION 5 Spurious parts may fail instanUy

during installation and lead to
consequenttaldamages

Suspension should be greased

regularly as per the recommended
maintenance schedule.
6 Stub axle cannot move freely
A CAUTION around king pin due to less or
no grease and thus stabilizer
can fail prematurely.
Air springs and bushes should be
protected from exposure to
chemicals. They should be
covered property while other
7 works are in progress

A CAUTION
Such exposure would reduce life
ofairspringandbushes

4
 PARALIFT SUSPENSION ~
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Do's and Don't's Q
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Sr. No. Do's and Donfs Photo

Do not use damaged or deflated

tyre on the axle .

A CAUTION 8 It leads to premature failure of

main air spring due to over
extension

Don't alter vehicle height by adding

extra leaves/removing leaves from
9 suspension or by any other means.

A CAUTION It leads to early failure of main

air spring due to overextension.

Don't tamper structural

components by drilling holes or
any structural alteration.
10
Alteration would weaken the
A CAUTION structural parts and can lead to
premature failure

Do not add spacer below axle seat.

A CAUTION 11 Spacer addition would damage

Stabilizer andleads to premature
failure

Don't alter the pneumatic circuit

or valves provided by OEM.
12 Such changes leads to
A CAUTION malfunctioning of lifting
system and would damage the
components.

Don't alter the Electrical circuit of

solenoid valve provided by OEM. Do
not shift the solenoid valve into the
driver's cabin for deploying the
13 system when needed.

A CAUTION
Lowering the axle while vehicle is
in motion would damage the
components and can be
dangerous at times.
Axle should be lifted as soon as
reverse gear is engaged. Vehicle
should be driven in reverse
14 direction only after the axle is lifted
completely.

A CAUTION Else stabilizer would fail

prematurely.

5
PARALIFT SUSPENSION •T• TATA [8JllENDRICKSOft

General Tools :- Table 4.1

S.No Fastener size Spanner & Socket Size Torque Values

1 M10 No.17 20Nm

2 M12 No.19 40Nm

3 M16 No.24 250Nm

4 M18 No. 27 280Nm

5 M20X1.5 No.30 60Nm

6 M20X2.5 No.30 370Nm

7 M27 No. 41 1200Nm

Table 4.2
SI Tools Type Size/ No.

1 Open spanner size 17, 19,20,22,24,27,30,32,34,37,41

2 Ring spanner size 17, 19,20,22,24,27,30,32,34,37,41

3 Socket size 17, 19, 20, 22, 24, 27, 30, 32, 34, 37, 41 (1" sqdr socket)

4 Deep socket size 17, 19, 20, 22, 24, 27, 30, 32, 34, 37, 41 (1" sqdr socket)

5 Extension for socket 5" long and 1O" long

6 Connector 1" (F) x 1" (M) connector

7 Plier Combination plier

8 Hammer Ball pin hammer

9 Mallet Standard mallet

10 Jack Hydraulic Jack of capacity up to 20T

11 Air pipe hose Air Pipe hose suitable for pneumatic nut runner

12 Pneumatic runner Pneumatic Nut runner

13 Torque wrench 50Nm, 275Nm, 370Nm, 550Nm, 940Nm, 1200Nm

Special Tools : Table 4.3

SI Description Remarks

1 Stabilizer Compress Fixture Stabilizer assembly on axle - Refer Below

2 Loctite 270 Liquid Loctite for Re tightening of M27 Pivot bolts

3 Pressure Gauge with Connector Main Air spring Pressure Measurement

6
•T•TATA IHl I ~ 11 ' j I- +.-: I
PARALIFT SUSPENSION :
~
Details of Special Tools 'ii

1. Stablllzer compressor fixture •

l:
Install stabilizer inside the special tool, this helps to fit the stabilizer in asaferway. 'i
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Fig. 4.1: Stabilizer compressor fixture Fig. 4.2: Stabilizer fitted into the fixture

2. Pressure Gauge with Connector-

Main Air Spring Pressure measurement
Connect to Main
air spring input side
• Connect pressure gauge

....______ _, -
Connect the main supply pipe,
which is coming from LACV
Fig.4.3: Fig. 4.4: Air Pressure Gauge
Adopter Female Size - 14 mm
Adopter Male size - 14 mm

STEP1 STEP2
Remove air Connection of Main Air Spring & Fit the main air spring original
Insert Adapter in its place male connector inside adapter

Fig.4.5 Fig.4.7
Fig.4.6 Fig. 4.8

STEP3 STEP4
Connect the pressure gauge The pressure in main air spring must
be 5.6 ± 0.2 bar

Fig.4.9 Fig. 4.10

7
PARALIFT SUSPENSION

Preparation:·
• Park the vehicle on pit/ ramp/ Plain Surface.
• Apply parking brakes.
• Remove air completely from the airtank &air springs.
• Ensure Genuine Fasteners are not used more than 3 times otherwise replace
fasteners with new Genuine Fasteners.
• Ensure lift axle should be in deployed position
General Instruction:-
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests
on the componentface.
• Ensure that flat side of Nut rests on washer.
• Ensure specific instructions to be followed for truck and prima segment as below
Table 5.1
E. Removal of Main Air Spring
SI Activity LPT 3118 (Ph-3) & 3718 Pusher Prima 3123.T & 3723.T

E1 Removal
of Main
Spring
Air
connection

E2a Remove
mounting
Flange Hex
Head Nuts
on Main
air spring

E2b Remove
HD M10 bolts
at the axle
seat

L M10 HD Bolt

8
•T•TATA tH1 : I:• I .j ~ .._: I
PARALIFT SUSPENSION !:II
,,
Removal of Main Air Spring
~
D.
~
SI Activity LPT 3118 (Ph-3) & 3718 Pusher Prima 3123.T & 3723.T .a
E
E2c Press the Main
air Spring by
hand to remove
stud from Upper
J
al
c
Air spring ·ca.
mounting plate U)
and remove it. ...
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Table5.2 'i
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E3. Assemble New Main Air Spring :I
E3a Press the air
u.i
spring, fit
between air
spring mounting
and axle seat
top plate.

E3b Insert Air

spring studs
in upper air
spring
mounting
plate holes

E3c Insert M20

and M12
nut and
torque it M12Flange M20 Flange hex
hex nut nut and tight

E3d Align Holes of

Main Air Spring
with axle seat, to ::: M10 Flange
insert M10 ftange HD. Bolt
head bolt

E3e Tighten the M10 Please avoid using pneumatic nut runner while tightening the air
flange head bolt spring M1Oftange bolts as it will lead to over tightening of the bolts.

E4 Pneumatic LPT 3118 (Ph-3) &3718 Pusher Prima 3123.T & 3723.T
Connection to
Main Air Spring

Note:
1) Follow similar Procedure for the Main air spring on the other side.
2) Please use preset torque wrenches for tightening.
3) ForFastenerTorquevalues referSection-N.

9
PARALIFT SUSPENSION •T•TATA [8J : I~ 11 . j 1-1 ..._:~I

Main Instruction:·
• Park the vehicle on pit/ramp/Plain Surface.
• Apply parking brakes.
• Remove aircompletelyfrom the airtank&airsprings.
• Ensure Genuine Fasteners are not used more than 3 times otherwise replace
fasteners with new Genuine Fasteners.
General Instruction:-
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests
on the componentface.
• Ensure that flat side of Nut rests on washer.

STEP - F1. Remove Air Connection STEP - F2. Remove mounting nuts
from Lift Air Spring on Lift Air Spring
Remove air connection Remove mounting nut and
from Lift air spring bolts of lift air spring

Fig. 6.1 Fig. 6.2

STEP - F3. Remove old lift air spring STEP - F4. Assemble New Lift air
spring
• Press the lift air spring to remove • Press the new air spring & insert
stud from beam assembly and between beam arms
remove it.
Prass Prass Press Press

Fig. 6.3 Fig. 6.4

10
41TtJTATA HJ : I :.ii I 'l t- .._: I
PARALIFT SUSPENSION ~

STEP - F5. Tight mounting &air connection Nuts

1
D..
b
• Insert M10 flange Bolt sand M20 Flange Hex nut. .Cl
• For Fastener Torque values refer Section - N. E

M10 Flange Bolts M20 flange Nut

J
CD

'•--
A c
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a.
rn

Fig.6.5 Fig.6.6

STEP • F6. Air Connection to Lift Air Spring

Connect with
_.,,.. Pneumatic hose

Fig.6.7
Note:
• Similar Procedure to be followed for the Lift air spring on the other side.
• For FastenerTorque values refer Section -N.

11
PARALIFT SUSPENSION •T•TATA rHJ

Main Instruction:·
• Park the vehicle on pit/ ramp I Plain surface.
• Apply parking brakes.
• Remove air completely from the airtank &air springs.
• Ensure genuine fasteners are not used more than 3 times otherwise replace
fasteners with new genuine fasteners
• Place jack under the Beam axle, to the side where the replacement of rebound
strap to be carried out.
General Instruction:·
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests
on the component face.
• Ensure that flat side of Nut rests on washer.

STEP· G1. Remove Rebound Clip on Axle Seat and Chassis

Remove All M16 nut. Flange bolt and
washer from the Chassis

Remove All M16 nut. Flange bolt and Remove All M16 nut, Flange Bolt. Remove
washer from the Chassis Rebound Clip from Axle Seat and Chassis Bolt
and washer on Axle Seat.
Fig. 7.1 Fig. 7.2
STEP· G2. Remove Rebound Clip from Rebound Strap
Remove both Rebound Clips from Rebound Strap and Replace the Rebound Strap
with Genuine Rebound strap.

Fig. 7.4 Fig. 7.3

12
41TtJTATA HJ : I :.ii I 'l t- .._: I
PARALIFT SUSPENSION ~

STEP • G3 Fit Rebound Clips on Chassis and Axle Seat

1
D..
B
Visually match all Rebound Clip holes "E
with frame holes and Axle Seat holes. Tighten M16 nuts cl
==~======:::=~~=:::'.====== ~======= =~·======~ a.
i
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.8
.I
c;

Fig. 7.5 Fig. 7.6

Note:
• Similar Procedure for other side Rebound Straps
• For Fastener Torque values refer Section-N.

13
PARALIFT SUSPENSION •T•TATA lHl :1 :-ii 11·1 H ~I

Images of Wear Pad Wear I Missing in field

Fig. 8.1 - Correct (Wear Pad Visible) Fig. 8.2 - lncorred. (Wear Pad Missing)

Main Instruction:·
• Park the vehicle on pit/ramp/Plain Surface.
• Apply par1<ing brakes.
• Remove air completely from the air tank &airsprings.
• Ensure Genuine Fasteners are not used more than 3 times otheruvise replace
fasteners with new Genuine Fasters.
General Instruction:-
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests
on the component face.
• Ensure that flat side of Nut rests on washer.
STEP· H1a. Remove air connection from Lift Air Spring

Remove air connection

from Lift air spring

Fig.8.3
STEP • H1 b. Remove air connection from Main Air Spring
Remove
LPT 3118 & 3718 Pusher air connection Prima 3123.T & 3723.T
~

Fig.8.4 Fig. 8.5

14
•TtJTATA (HJ : I :~ I I 'i I- .....:~I I
PARALIFT SUSPENSION ~
1e
STEP- H1c. Remove mounting nut and bolts on Lift Air Spring 111.

Remove mounting nut and

8
bolts on lift air spring -~
cl
"D
ca
...ca
111.

~ I

Fig.8.6
STEP - H2. Loosen Z section from Hanger
Ensure applying of rigid stand beneath axle such that the axle load will be taken
by the stands

Fig. 8.7

STEP· H3. Remove Bottom Beam Assembly and Wear Pad

• Remove both side M27 Hex Head Bolt, Nut and washer
• Remove bottom beam assembly with old wear pads.
Remove both side M27 Hu Head Bolt, Nut and washer
~

Fig.8.8

Remove bottom beam assembly and old wear pad

15
PARALIFT SUSPENSION •TtJTATA (HJ I ;i . I I : l 1-l .._:- I

STEP· H4. Remove Top Beam Assembly and Wear Pad

• Remove both side M27 Hex Head Bolt, Nut and washer
• Remove M16 Hex Head Bolt, Nutandwasherand disassemble the Rebound dip
• Remove old top Beam assembly with old wear pads
1) Remove both side M27
Hex Head Bolt, Nut and washer

\I

2) Remove M16 Bolt, Nut and

washer and dis assemble
the Rebound clip

Fig.8.9 Fig. 8.10

3) Remove top Beam

assembly and
old wear pad

Fig. 8.11

STEP· H5a. Fit Top Beam Assembly with New Wear Pad
First Assemble Top Beam assembly then Bottom beam assembly

~ Fig.8.12

Put Top Beam Assembly with new wear pad

16
&TATA l8J '. • I I ~ ~ ·I
PARALIFT SUSPENSION ;

STEP· HSb. Tlght Nuts, Bolt and Washer J

• Apply Loctite 270 (i.e. liquid Loctite 2-3 drops) to the threads of M27 bolts before
tightening.
• Assemblethe Rebound clip and tighten the M16 bolts, nuts and Washer.
• For FastenerTorque values refer Section-N.
I
'a

..
l.

Pill lop beam 8&68mbly with

~ newwearpads
'I
::c

Fig. 8.13 AJV! holes, Insert M27 hex

Head boll, weaher & Nut

Assemble the Rebound clip ind

tighten the M16 bolls, nuta and
washers

Fig. 8.14
Tight M27 Hex Head bolls,
nuts and washel'

STEP· H6a. Flt Bottom Beam Allembly with New Wear Pad

Fig. 8.15

Put Bottom Beam Assembly with new wear pad

17
PARALIFT SUSPENSION 41T9'TATA HJ ;1;..i I 'll~ i-: I

STEP· H6b. Tighten M27 Nuts, Bolt and Washer

• Apply Loctite 270 (i.e. liquid Loctite 2to 3drops) to the threads of M27 bolts before
tightening.
• For Fastener Torque values refer Section - N. (For latest updates, refer latest
released service circular)
Put bottom beam Assembly
wi1h new wear pads

Fig. 8.16
Aligned holes and insert M27 Hex
Head Bolts, nuts and washer

Fig. 8.17
Tight M27 Hex Head bolts,
nuts and washer

STEP H7. Ensure the Placement of Wear Pad

Fig. 8.18
New wear pad
Fig. 8.19 v
New wear pad at
at hanger side Axle Seat side

18
•T•TATA tHJ PARALIFT SUSPENSION ;

STEP H8. Assemble Lift Air Spring

I
D.
• Tighten M10 Flange HD bolts and M20 Flange B
• For Fastener Torque values refer Section - N.
(For latest updates, refer latest released service circular) l
i
Press the lift air spring & Tigtrten M10 Flange HD bolts and M20 Flange
insert Between beam anns Hex Head Nut and Connect wi1h air hose

Fig. 8.20 Fig. 8.21

STEP - H9. Tighten Z Section Botts

• Tighten M16 Flange Head bolt, nuts and washer as per specified torque
• For Fastener Torque values refer Section - N.
(For latest updates, refer latest released service circular)

Tighten M16 Flange Head bolt, nuts and Fig. 8.23

washer as per specified torque
Fig. 8.22
Note:
• Similar Procedure for other side Wear Pad.
• For Fastener Torque values refer Section - N. (For latest updates, refer THSL
drawing 01AX081Z00/01AX041 ZOO with latest issue level)

19
PARALIFT SUSPENSION 4rT•TATA tHl : I ;ii 11 ' j 1-1 4--:~ II

ll!i:E!Ymll Main Instruction:-

• Park the vehicle on piVramp/Plain Surface.
• Apply parking brakes.
• Remove air completely from the air tank &air springs.
• Ensure Genuine Fasteners are not used more than 3 times otherwise replace
fasteners with new Genuine Fasters.

General Instruction:-
• Ensure that chamfered side ofwasher is towards Nut (or bolt) and flat side rests on
the component face.
• Ensure that flat side of Nut rests on washer.

STEP· 11 a. Remove air connection from LiftAir Spring

Remove air connection

from Lift air spring

Fig. 9.1

STEP-11b. Remove air connection from Main Air Spring

LPT 3118 & 3718 Pusher Remove Prima 3123.T & 3723.T
air connection

Fig. 9.2 Fig. 9.3

STEP - 11.c. Remove mounting nut and bolts on Lift Air Spring

Remove mounting nut and

bolts on lift air spring

Fig.9.4
20
•T•TATA (HJ PARALIFT SUSPENSION !:I

STEP -12c Loosen zsection from Hanger

Ensure applying of rigid stand beneath axle such that the axle load will be taken
J
.I
by the stands ~

Loosen All M16 flange Head Bolt, nut

rl
)
,Q

..
I.
I
f
i:
•
.B.
FJg.9.5 -
STEP· 13. Remove Bottom Beam Assembly and Wear Pad
• Remove both side M27 Hex Head Bolt, Nut and washer
• Remove bottom beam assembly with old wear pads.
Remove both side M27 Hex Head Bolt, Nut and washer

FJg.9.6

STEP -14. Remove Top Beam Assembly and Wear Pad

• Remove both side M27 Hex Head Bol~ Nut and washer
• Remove M16 Hex Head Bolt, Nut and washer and dis assemble the Rebound clip
• Remove old top Beam assembly with old wear pads
1. Remove both side M27 Hex Head Bot~ Nut 2. Remove M16 Bot~ Nut and washer
and washer Remove bottom beam assembly and dis assemble the Rebound clip
and old wear pad /\
l"'!"'l'MP. . ."P""!!"t

Ag. 9.7 Flg.9.8

21
PARALIFT SUSPENSION •T•TATA rHJ-

, 3. Remove top Beam assembly

and old wear pad
Fig.9.9

Step 15. Remove Inner metal sleeves from beam assembly

Remove the Inner metal sleeve from beam assembly

Step 16. Remove rubber bushes from beam assembly

Fig. 9.11 Remove the rubber bushes from beam assembly

Step 17. Insert new rubber bushes into the tube of beam assembly

Fig. 9.12

22
•T•TATA rH1 : I ;. 11 ' I H ..._, I
PARALIFT SUSPENSION !
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• 4.5mm to 6.5mm
-~
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Fig. 9.13 Check the height of rubber bush face to beam rube face within 4.5 to 6.5 mm ...
.!
Step 18. Insert Inner metal sleeve into rubber bushes ::I
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Fig. 9.14 Insert Inner metal sleeve into rubber bushes

STEP • 19.a. Fit Top Beam Assembly with New Wear Pad
First Assemble Top Beam assembly then Bottom beam assembly

~
Fig. 9.15

Put Top Beam Assembly with new wear pad

STEP -19.b. Tight Nuts, Bolt and Washer

• Apply Loctite 270 (i.e. liquid Loctite2-3 drops) to the threads of M27 bolts before
tightening.
• Assemble the Rebound clip and tighten the M16 bolts, nuts and Washer.
• For FastenerTorque values refer Section-N

,,.. Put top beam assembly with new wear pads

Align holes, insert M27 hex Head bolt,

washer& Nut

23
PARALIFT SUSPENSION •T•TATA fH1 ; I ;.ii I . t t- 4-:~ I

Assemble the Rebound clip and tighten the

M16 bolts, nuts and washers

Fig. 9.17 3. Tight M27 Hex Head bolts, nuts and washer

STEP· 110.a. Flt Bottom Beam Assembly with New Wear Pad

Fig. 9.18
,._
Put Bottom Beam Assembly with new wear pad

STEP· 110.b.Tighten M27 Nuts, Bolt and Washer

• Apply Loctite 270(i.e. liquid Loctite 2 to 3drops) to the threads of M27 bolts before
tightening.
• For FastenerTorque values refer Section· N.

Put bottom beam r sembly with new wear pad•

24
41T1'TATA (HJ I :• I I ' l 1-i .... I
PARALIFT SUSPENSION !
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B
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Fig. 9.21 ...
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STEP -111. Ensure the Placement of Wear Pad •
:II
m

Fig.9.22 V
New wear pad at hanger side New wear pad at Axle Seat side

STEP· 112. Assemble Lift Air Spring

• For Fastener Torque values refer Section - N. (For latest updates, refer THSL
drawing no.01AX081 Z00/01AX041ZOOwith latest issue level)

Press the lift air spring &insert M20 Flange Tighten M10 Flange HD bolts and
Between beam arms Hex Head Nut and Connect with air hose

Fig. 9.24 Fig. 9.25

25
PARALIFr SUSPENSION

STEP· 113. Tighten Z Section BoHs

Fig. 9.26

Tighten M16 Flange Head bolt, nuts and washer as per spedfled torque

Note:
• Similar Procedure for otherside to replace Beam bushes
• For FastenerTorque values refer Section - N

Main Instruction:·
• Parkthevehicieon pit/ramp/Plain Surface.
• Applyparkingbrakes.
• Remove aircompletelyfrom the airtank&airsprings.
• Ensure Genuine Fasteners are not used more than 3 times otherwise replace
fasteners with new Genuine Fasteners.
• Ensure applying of rigid stand beneath axle such that the axle load will be taken
bythe stands.
General Instruction:·
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests
on the component face.
• Ensure that flat side of Nut rests on washer.

26
•T•TATA (HJ : I ;:ii I 'I ~ ...._;~I
PARALIFT SUSPENSION l!
::::s

12
General Instruction:- a.
• Ensure that chamfered side of washer is towards Nut (or bolt) and flat side rests 3
on the component face.
• Ensure that flat side of Nut rests on washer.
]...
STEP • J 1. Place the fixture on to the stabilizer neck -J!•
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Put Stabilizer Fixture on stabilizer neck
Fig.10.1
STEP • J2. Remove old Stabilizer
Put Stabilizer Fixture on stabilizer necks on both side then Loose M18 Nuts and
Remove Stabilizer

Remove M18 Flange Head Bolt and nut Remove Old Stabilizer
Fig.10.2

STEP • J3a. Fit New Stabilizer

Fig.10.31/f/////!"

i
New Stabilizer press in stabilizer fixture

27
PARALIFT SUSPENSION •T•TATA (H)H*-Hmm

STEP· J3b. Align Holes & Insert M18 Flange bolts

Fig.10A

STEP· J3c. lighten M18 Nuts as per Specified Torque

• lighten M18 Flange bolt and nut/washer then remove stabilizerfixture.
• For Fastener Torque values refer Section • N

Fig. 10.5
light M18 Flange bolt and nut

Note:
• Please ensure that M18 bolt length should be 1OOmm ataxle
• Similar Procedure for other side Stabilizer.
• For Fastener Torque values refer Section • N

28
t
PARALIFT SUSPENSION •T•TATA HJ ; I :-a 11 'l 1-i ~:~I

Table 12.1
SL No. List of serviceable parCs THSL Part Noa. lMLPartNoa.
1 Bush outer rubber 86CX037C01 2846 3390 34 09
2 Bushing Inner steel 86CX038C01 2846 3390 3411
3 Wear pad 95CX217C01 2846 3390 99 31
4 Lift Air springs 41CX008C01 2846 3390 99 34 or
2846 3390 99 56 or
2846 3390 99 73
5 Main Air Springs 41CX014C01 2846339099 72 or2846 3390 99 73
6 stabilizers 44AX007C01 284633909937 or2846 3390 99 53
7 Rebound Strap 86CX049C01 5043 3390 33 07
For Part Nos. related to fasteners please ref'er Section - N

M - GAP Measurement
between Axle Seat &
External Bump stop
Axle Seat Top plate to External Bump Stop Gap in Lift Condttion.
Normal Operating Range 5mm to 10mm

Fig. 13.1

30
•T•TATA HJ : I : 1 11 'l H ~:~I
PARALIFT SUSPENSION I
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N. Part No. Cross reference &Torque Values
i) Torque Values 311813718 Pusher
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Table 14.1
ITEINO. lHBL PART NUMBER TML PART NUMBER DESCRIPTION QIY.
1 10CL031C01 5043 3390 33 08N HANGERLH 1
2 10CR031C01 5043 3390 33 09N HANGERRH 1
3 95CX246C01 5043 3390 33 06N USECTION 2
4 51CX021C01 2846 3390 02 25 ZSECTION 1
5 31AL.136C01 2846 3390 03 39N AXLESEATLH 1
6 31AR136C01 2846 3390 02 92N AXLE SEAT RH 1
7 24AL.02llC01 2846 3390 02 93N BEAM ASSEMBLY LH 2
8 24AR028C01 2846 3390 02 94N BEAM ASSEMBLY RH 2
9 95CX217C01 2846 3390 99 31 WEAR PAD 16
10 41CX008C01 2846 3390 99 34 OR LIFT AIRSPRING 2
2846 3390 99 56 OR
2846 3390 99 58
11 41CX014ZOO 2846 3l90 99 72N OR
2846 3390 99 73N MAIN AIR SPRING 2
12 44AX007ZOO 2846 3390 99 37 OR STABILIZER
2848 3390 99 53 (STEERING DAMPER) 2
13 11AL.046ZOO 2846 3390 02 95 AIR SPRING MTG LH 1
14 11AR046ZOO 2846 3390 02 91 N AIR SPRING MTG RH 1
15 32AL011ZOO 2848 3390 02 97N EXTERNAL. BUMP
STOP ASSEMBLY LH 1
16 86CX049Z.OO 5043 3390 Tl 01 REBOUND STRAP 2
17 32CX031ZOO 5043 3390 33 07 REBOUND CLIP FINISHED 4
18 3.2AR011ZOO 2846 3l90 02 98N EXTERNAL. BUMP STOP
MSEMBLYRH 1

31
PARALIFT SUSPENSION &TATA ;I ;.ii I ' t t- 4-:~ I .

Scopa of Supply • THSL Table 14.2

ITEMNO. THSlPARI' TMLPART DESCRIPTION QTY.
NUMBER NUEER
19 &3CX007C01 2846 3390 3359N M20x1.5 CCI.ASS 10.FLAHGE HEX HEAD NUTI 2
20 90CX010C01 2846 3390 3363N M16x2x6<X.GGRD.10.9Fl.ANGEHD. BOLT 8
2.1 &2CX102001 2846 3390 3357N M16 x2(GRD10.0 All. METAL PREVAILING roRQUE NUT) 12
22 90CX034C01 2846 3390 3362N M10x1.5 x 25 LG (GRD. 8.8 Fl.ANGE HD. Ba.T) OR
M10x1.5 x 25 LG (GRD. 10.9 Fl.ANGE HD. BCll} 4
2.1 &1CX129C01 5039 3390 3367N M2T.x3x200LG GRD 1o.& HEX HD BOLT 4
24 91CX130C01 6039 3390 3368N M27x3x210LG GRD 10.9 HEX HD BOLT
2.5 &2CX113C01 5039 3390 3361N M21x3IGRD10.0 HEX NUTI '
8
28 94CX101C01 5039 3390 331 !iN M2T HARDENED WASHER 16
27 94CX104C01 2846 3390 3312N M16 HARDENED WASHER 16
48 &1CX12e001 11064018620N M16X2.ll>C704IGRD 10.9 HEX HD 90!.T 4

Scope of Supply· TML Table 14.3

ITEMNO. TlllL PART NUMBER DESCRIPTION QTY.
28 2846 3390 3318N M20 HARDENED Pl.AIN WASHER 8
29 124C!(J5010S7N BRIGHT WASHER 10.51S21>16 ST SSIM51-8C 4
30 2846 3390 3363N M16X2.0XSO LG...fl..AHGE BOLT -10.9 26
31 5011 32AO 85 03N HEX Fl.ANGE NITT (SELF LOCKING) M16X210.9 26
32 5006 3240 3213N HEX FL BOLT M18X2X70 4
33 2846 3390 3362N M10X1.5X25 LG..fl.ANGE BOLT ·10.9 4
34 2846 3390 3364N M18X2.5X130 IA-Fl.ANGE 90!.T ·10.9 2
35 5009 3240 32 ~ HEX FL BOLT M18X2.5X100 2
36 2846 3390 3358N M18X25 ·AMPT NUT-10 4
37 2846 3390 3335N M18-HARDENED PLAIN WASHER 4
38 11071712551N HEX FLBOLTM12X55TS1713010.9SS8451-8CH 2
39 110T1510559N HEX FL BOLT M10X55 TS17131).8.8.sS8451S2-Y 4
40 2846 3390 3360N M20X2.s.AMPT NUT·10 8
41 12G51598073N HEX NUT M10 IS1364P3-3-SS8451-&C 4
42 2846 3390 3356N M12X1.75-FLANGE. HEXNUT-10 2
43 2846 3390 3365 M20X2.5X75 LG...fl..AHGE BOLT -10.9 8
44 2846 3390 3359N M20X1.5-Fl.ANGE HEX NUT-10 2
4S 12143401209N HEX FL NUT M12X1.5ISO1212610 SS8451-8CH 2
48 2846 3390 3312N M16 IWUlENE.D PLAIN WASHER 4
47 2846 3390 3357N M16X2-AMPTNUT·10 4

32
•T•TATA (HJ I ;. II .i 1-i t...: I
PARALIFT SUSPENSION I
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N. Part No. Cross reference & Torque Values ::I
ii) Torque Values 3123.T/3723.T Prima e-
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Table 14.4
ITEMNO. PART NUMBER TML Patt Numbtr DESCRIPTION QlY. *BOM FOR BEAM ASSEMBLY LH (1AAL028C01) Table 14.4a
1 10CL031C01 5043 3390 33 08N HANGERUi 1 24AL028C01
2 10CR031C01 5043 3390 33 09N HANGER RH 1 PART NUMBER BIL PART DESCRIPTION QTY
3 95CX246C01 5043 3390 33 06N USECTION 2 NUMBER
4 51CX021C01 2848 3390 02 25 ZSECTION 1 24AL025C01 2848 3390 03 47N BEAM ASSEMBLY 1
5 31AL136C01 2848 3390 03 39N AXLE SEAT Ui 1 WELDMENTLH
6 31AR136C01 2848 3390 02 92N AXLE SEAT RH 1 86CX037C01 2848 3390 34 09 BUSH OUTER RUBBER 2
7 24AL028C01 2848 3390 02 93N BE'AM ASSEMBlY Ui 2 86CX038C01 2848 3390 3411N BUSHING INNER STEEL 2
8 24AR028C01 2848 3390 02 94N BE'AM ASSEMBlY RH 2
9 95CX217C01 2848 3390 99 31 WEAR PAD 16
10 41CX008C01 2848 3390 9934 OR LIFT AIR SPRING 2
2848 3390 99 56 OR
2848 3390 99 58
11 41CX014ZDO 2848 3390 99 72N OR MAIN AIR SPRING 2
2848 3390 99 73N • BOM FOR BEAM ASSEMBLY RH (24AR.028C01) Table 14.4b
12 44AX007ZOO 2848 3390 99 37 OR STABILIZER 2 24AR028C01
2848 3390 99 53 (STEERING DAMPER) QTY
PART NUMBER TMLPART DESCRIPTION
13 11AL045ZOO 5043 3390 01 23 AIR SPRING MTG Ui 1 NUMBER
14 11AR045ZDO 5043 3390 0122N AIR SPRING MTG RH 1
24AR025C01 2846 3390 03 48N BE'AM ASSEMBlY 1
15 32AL011ZOO 2848 3390 02 97N EXTERNAL. BUMP STOP 1 WELDMENTRH
ASSEMBLYUi
86CX037C01 2846 3390 34 09 BUSH OUTER RUBBER 2
16 32AR011ZOO 2848 3390 02 98N EXTERNAL. BUMP STOP 1
ASSEMBLY RH 86CX038C01 2846 3390 3411 N BUSHING INNER STEEL 2
17 86CX049ZDO 5043 3390 01n REBOUND STRAP 2
18 32CX031ZOO 5043 3390 33 07 REBOUND CUP FINISHED 4

33
PARALIFT SUSPENSION •T• TATA [H]llENDRICKSOll

AIR SPRING MOUNTING (1 1AL045Z00&1 1AR045Z00)

MUST BE IN CONTACT WITH THE UNDERSIDE OF CHASSIS RAIL
BEFORE TIGHTENING FASTENERS
/'.-"",--.. .,,
( 3 1 :. 30 ,I
·....__ / '-._ /
(TORQU[ l~ONm. - l 0%)
f'RELOAD 88kN.(4x)

~ ,--,
• .._j 33 '
\:._'./
TORQ LI [ 20Nrn: 203.(4x)

@@G_)
~~m~~=~2x1x-m 1

TML TO PROVIDE SPACER BETWEEN

CHASSIS FRAME & HANGER
NOTE: FOR STRUCTURAL INTEGRITY OF
CHASSIS ANO SUSPENSIO N SYSTEM: PRELOA0275kN
SPACER MUSTSUPPORT FRONT BEND TORQUE 1200Nrn -l-<} -203 ,(4x)
FLANGE OF HANGER ~:~

PRELOAD275kN
TORQUE 1200Nrn +O-LO'lo.(4x)

f t·

Scope of Supply - THSL Table 14.5

ITEM NO. PART NUMBER TMLPART DESCRIPTION QTY.
NUMBER
19 93CX007C01 2846 3390 3359N M20 x 1.5 (CLASS 10.FLANGE HEX HEAD NUTI 2
20 90CX010C01 2846 3390 3363N M16 x 2 x 60LG GRD. 10.9 FLANGE HD. BOLT 8
21 92CX102C01 2846 3390 3357N M16 x 2 (GRD 10.0 ALL METAL PREVAILING TORQUE NUl) 12
22 90CX034C01 2846 3390 3362N M10x1.5 x 25 LG (GRD. 8.8 FLANGE HD. BOLT) OR 4
M10 x 1.5 x 25 LG (GRD. 10.9 FLANGE HD. BOLT)
23 91CX129C01 5039 3390 3367N M27x3x200LG GRD 10.9 HEX HD BOLT 4
24 91CX130C01 5039 3390 3368N M27x3x210LG GRD 10.9 HEX HD BOLT 4
25 92CX113C01 5039 3390 3361 N M27 x 3 (GRD 10.0 HEX NUTI 8
26 94CX101C01 5039 3390 3315N M27 HARDENED WASHER 16
27 94CX104C01 2846 3390 3312N M16 HARDENED WASHER 16
49 91CX126C01 11064016620N M16X2.0X70Lg GRD 10.9 HEX HD BOLT 4
Scope of Supply - TML Table 14.6
ITEM NO. TML PART NUMBER DESCRIPTION QTY.
28 2846 3390 3318N M20 HARDENED PLAIN WASHER 8
29 12460501057N BRIGHT WASHER 10.5 IS2016 ST SS8451-8C 4
30 2846 3390 3363N M16X2.0X60 LG.-FLANGE BOLT -10.9 8
31 5011 3240 65 03N HEX FLANGE NUT (SELF LOCKING) M16X210.9 2 6
32 5011 3240 3217 M16 x 2 x 90LG GRD. 10.9 FLANGE HD. BOLT 18
33 2846 3390 3362N M10X1 .5X25 LG.-FLANGE BOLT-10.9 4
34 2846 3390 3364N M18X2.5X130 LG.-FLANGE BOLT -10.9 2
35 5009 3240 32 05N HEX FL BOLT M18X2.5X100 2
36 2846 3390 3358 M18X2.5-AMPT NUT-10 4
37 2846 3390 3335N M18-HARDENED PLAIN WASHER 4
38 11071712 551N HEX FL BOLT M12X55TS1713010.9SS8451-8CH 2
39 11071510559N HEX FL BOLT M10X55 TS17130-8.8-SS8451S2-Y 4
40 2846 3390 3360N M20X2.5-AMPT NUT-10 8
41 12051598073N HEX NUT M10 IS1364P3-8-SS8451~C 4
42 2846 3390 3356N M12X1 .75- FLANGE HEX NUT-10 2
43 2846 3390 3365 M20X2.5X75 LG.-FLANGE BOLT -10.9 8
44 2846 3390 3359N M20X1 .5-FLANGE HEX NUT-10 2
45 12143401209N HEX FLNUTM12X1.5ISO1212610 SS8451~CH 2
46 5006 3240 3213N HEX FL BOLT M16X2X70 4
47 2846 3390 3312N M16 HARDENED PLAIN WASHER 4
48 2846 3390 3357N M16X2-AMPT NUT-10 4

34
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TATA AUTOCOMP HENDRICKSON SUSPENSIONS PVT LTD

Gat No. 431/1, Medankarwadi, Chakan -Alandi Road, Off. Pune - Nashik Highway,
Near Hotel Gandharwa, PLINE - 410 501 I Tel:+912135670670 I Email: service@tacohendrickson.com