Vous êtes sur la page 1sur 20

D55T-10x6

Standard Operating Procedures


& Maintenance Manuals

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

Congratulations for your purchase of a DRAMIS D55T. In this document, you will
find important information that will help you maximize the performance as well as
provide you with preventive maintenance guidelines.
Read and follow all safety instructions, this manual has to be kept in vehicle
A parts catalog has been forwarded to you management for front and rear
suspension as well as added systems. It is required to use only original parts. This
includes parts for hydraulic systems, automatic greasing system, on board load
scale, truck body vibrator and any other equipment installed/modified by DRAMIS
on the chassis. Use of non-original parts will automatically void warranty.
We are also available for any questions at the following:

DRAMIS International
800-423-5347
418-435-5347
info@DRAMISintl.com
www.DRAMISintl.com

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

INTRODUCTION

INTRODUCTION ............................................................................................................................... 2
1. General Safety Instructions ........................................................................................................ 4
2. General operating descriptions .................................................................................................. 6
2.1 DTS Hydro-pneumatic Dynamic Truck Suspension ......................................................... 6
2.1.1 Maximum Speed .......................................................................................................... 7
2.1.2 Maximum Payload (weight) ......................................................................................... 7
2.1.3 Leveling Limitations ..................................................................................................... 8
2.1.4 Road Grade.................................................................................................................. 8
2.1.5 Dump Body Unloading Procedure................................................................................. 8
2.1.6 Adjusting Ride Height .................................................................................................. 9
2.1.7 Operating Ride Height Procedure ................................................................................. 9
3. Maintenance and break-in Guidelines .......................................................................................10
3.1. Break in schedule .........................................................................................................11
3.2. Oil level check procedures ............................................................................................12
4. Maintenance ............................................................................................................................14
4.1. Preventive ....................................................................................................................14
4.2. Predictive .....................................................................................................................14
5. Front Twin Steer Alignment ......................................................................................................16
6. Trouble Shooting ......................................................................................................................17
7. Warranty ..................................................................................................................................19
Annexes Separate documents sent with Information Package
D55T- SERVICE TABLES
DTS REAR SUSPENSION USER MANUEL & Hydraulic Schematic
D55T - Suspensions break down and parts list
Bibeau Dump Body Parts manual
MAILHOT Cylinder user manual
AUTOMATIC GREASING SYSTEM TWIN 3 (GROENEVELD)
Air-Weigh calibration and operations manual

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /06-10-15

GENERAL SAFETY INSTRUCTIONS


Operators must read, understand and be aware of these general safety instructions. Before operating vehicle a full inspection
must be done to ensure that all equipment and its safety equipment are available and work properly. You will find in this manual a
number of alert messages, please take time to read and follow them. They are there to protect you and to avoid any costly
damaged to your vehicle.

WARNING
This symbol signals something that could cause an injury or death. This symbol will tell what the hazard is and what can
happen.

CAUTION
Caution symbol warns about serious damage that could be caused to vehicle.
There are 7 warning lights in truck cab to warn you when something needs attention.

3 warning lights: when suspension low oil level warning; Rear suspension return filter clogging warning; Rear
Suspension filter clogging warning

2 warning lights: Dump body low oil level warning when there is clogging in dump body return filter as well as
suspension pressure and return filters. Special note about dump body filter light. It is normal that it turns on while
body is coming down. This is caused by backpressure in the system due to high flow and doesnt mean filter is clogged.
It indicates filter clogging when it turns on as soon as PTO is engaged (after successful leveling)

1 warning light: Rear Suspension error warning; Rear suspension pressure filter clogging warning.

1 warning light for proper dump body position (It is normal that this warning light turns on when dumping). This is
light labelled rear suspension disabled. It will come on as soon as dump body starts lifting and wont come off until
dump body is back down on frame. When this light is on, rear suspension stops any adjustments for safety reasons

If any of these warning lights come on, it is important to check and apply the corrective action as soon as possible. Refer to
troubleshooting section or OEM manuals.

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

AVOID MOVING THE TRUCK WHEN THE DUMP BODY IS RAISED!

DO NOT EXCEED THE MAXIMUM VEHICLE GROSS WEIGHT RATING (GVWR)!

WHEN THE DUMP BODY IS RAISED FOR MAINTENANCE OR REPAIRS, IT MUST BE SECURED SO THAT IT CANNOT FALL
DOWN. FAILURE TO APPLY THIS PRECAUTION CAN RESULT IN SERIOUS INJURY OR DEATH!

DRIVER MUST OPERATE AT PROPER SPEED ACCORDING TO ROAD AND GROUND CONDITIONS.

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

1. General operating descriptions


2.1 DTS HYDRO PNEUMATIC DYNAMIC TRUCK SUSPENSION
There are two buttons for rear suspension function.
The button labelled Up/Down is used to raise or lower the suspension right height and to adjust suspension ride height at
stand still or low speed. Suspension will automatically go back to operating ride height when vehicle speed reaches 10 Km/h.
The button labelled Operating Ride Height Level is used to bring the suspension back to normal operating height after a
leveling cycle or after having changed ride height using the up/down button.
To readjust suspension height, press and maintain ON the Operating Ride Height button.

In both cases, when the vehicle reaches 10km/h, the suspension will automatically go back to normal operating ride height.
Photo Position Down

2015 DRAMIS International inc. All rights reserved

Photo Position Up

Ver 1.0 /06-10-15

2.1.1 Maximum Speed


Adopt vehicle speed according to the road conditions and in accordance with payload. The vehicle GVWR
is 81601Kg /179 900lbs *; speed should not exceed 50Km/h laden and 80-Km/h unladen and should be reduced
depending on road and / or weather conditions.
*GVWR is displayed inside driver side door on compliance label

In order to avoid engine over speed and to prevent overheating brakes, reduce vehicle speed to a minimum
before descending hill and if possible use engine brake or transmission retarder.
2.1.2 Maximum PayLoad (weight)
The recommended maximum load is 55 metric tons / 55000kg / 121254LBS /60627 tons (US). Do not overload
the Dump body. Make sure vehicle is in a stable ground before loading and that material is evenly distributed in
the body. Failure to follow this recommendation will void warranty.

The vehicle may be unstable and damages can be caused to hydraulic and / or mechanical
components if the load exceeds maximum payload of 55 metric tons/55000kg/121254LBS/60.627 US tons.

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

2.1.3 Leveling Limitations


During unloading process, the Maximum lateral grade should be 7 degrees or less. If the slope is greater than 7
degrees a warning alarm (beep) will be heard and the suspension will not level out.

2.1.4 Road grade


Under ideal road conditions, the vehicle load is designed to operate on a maximum grade of 20%. Operation on
grades greater than 20% is not recommended and will void warranty.

Maximum Tilt Specifications


You must have proper and appropriate overhead clearance before dumping.
2.1.5 Dump Body Unloading Procedure
1.
2.
3.
4.

Stop the vehicle


Engage parking brakes.
Engage PTO Vehicle cannot be in movement
Once the PTO is engaged, if the ground has an inclination the suspension leveling process will begin. There will be a
5 seconds delay before the Dump body begins to rise.

5.

Once the Dump body is lifted its very important to limit the movement of the vehicle, because the
suspension is no longer laterally stabilized. If the truck is moved during unloading, there is a very high risk of roll
over! If you have no choice and need to move the vehicle release slowly the service brake. Again, moving the truck
while the Dump body is raised is an extremely dangerous maneuver! If you have to move the vehicle, use very slow
speed and avoid sudden maneuvers.
When Dump body is completely empty apply brakes gently and lower the Dump body.

6.
7.

It is important that the Dump body has been completely lowered onto the truck chassis before you move
the vehicle. If not, a warning alarm will turn on.

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

Command and control of dump body unloading


Body cannot be lifted unless PTO is engaged. If lateral grade is higher than 7deg, suspension will not be able to level,
suspension error light will come on and PTO will not engage. During leveling operation a warning sound will be heard.
Operator must then reposition truck and try leveling suspension once again before dump operation.

2.1.6 Adjusting Ride Height


To ease loading and/or vehicle maintenance you can use this option by activating the Up/Down button to adjust the height
of the vehicle. From normal operating height this operation will raise or lower the vehicle no more than 4 inches. The height
will set back to normal operating position automatically when the truck reaches 10 km/h. It can also be done manually by
holding the Operating Ride Height button.

Refer to Rear Suspension on page 3 for detailed instructions.

2.1.7 Operating Ride Height Procedure


This operation is to bring the vehicle back to normal suspension ride height. This operation is done automatically when the
truck reaches 10km/h. It can also be done manually by pushing the Ride Height adjustment button down until long beep
notification warning is heard.

Refer to Rear Suspension on page 3 for detailed instructions.


REFER TO SCHEDULE 8.2 FO FULL DTS OPERATING AND MAINTENANCE

2015 DRAMIS International inc. All rights reserved

Ver 1.0 /22-12-15

3. MAINTENANCE AND BREAK-IN GUIDELINES


Although your DRAMIS truck has been thoroughly inspected during its production process, special care must be taken during
the break-in period common to any new equipment. Perform the following inspection points during the vehicles first 600
operating hours.

The hydraulic system on rear suspension is always in high pressured mode even if the truck engine has been shut off
for several hours/days. See pressure release procedure Failure to follow pressure release procedure may result in serious
injury and even death.
Pressure relief procedure
Even though engine is turned off, there is always pressure in the rear suspension hydraulic system. Below is the procedure
to relief pressure in the system when required (in order to change a hose for example).
Start the engine and lower the suspension on spacer blocks or all the way to the bump stops using the ride height adjustment
button down function. Keep holding the button in down position for a few minutes after suspension has reached blocks
or bump stops. This will relief most of the pressure in the system but there will still be some residual pressure.
To relief the residual pressure, slowly loosen hose fitting on one of the rear suspension accumulators while keeping a
container close to hold the oil that will leak out. Repeat on corresponding accumulator on opposite side.
System is now completely relieved of any pressure and it is now safe to work on it.

2015 DRAMIS International inc. All rights reserved

10

Ver 1.0 /22-12-15

3.1 Break in schedule

TABLE1
FRONT AND REAR SUSPENSION BREAK-IN PERIOD SCHEDULE *
SYSTEM: GENERAL
INTERVALS (HOURS)
#
1
2**
3

7
8
9
10

11
12
13 ***

ACTION
Tighten budd wheel nuts to 450-500 lbft of
torque.
Tighten rear wheel nuts to 250-275 lbft of
torque.
Check all oil levels (steering, dump cylinder
and rear suspension)
Inspect all hydraulic systems (steering, dump
cylinder and rear suspension) for any oil leak.
Take appropriate corrective action(s) if
required.
Inspect all steering and suspension
components for any loose fasteners and pay
attention for any unusual noise. Take
appropriate corrective action(s) if required.
On all rear suspension torque rods , tighten
7/8 inch bolts to 525 lbft and 3/4 inch bolts
to 358 lbft.
On all front suspension torque rods , tighten
5/8 inch bolts to 198 lbft and 1 1/8 inch bolts
to 1264 lbft.
On front axles, tighten U-bolts to 665 lbft. **
On rear axles, tighten 7/8 inch U-bolts to 440
lbft and 1 inch U-bolts to 665 lbft. **
Inspect all automatic greasing system for a
broken or worn hose. Take appropriate
corrective action(s) if required.
Check for proper and equal (side to side)
tension of dump body automatic door cable.
Take appropriate corrective action(s) if
required.
Check all tire pressure.
Inspect all spoke wheel assemblies for wheels
that may have slipped relative to hub. Take
appropriate corrective action(s) if required.

16

48

100

200 400 600

X
X

* Although your suspensions have been thoroughly inspected, base inspection must be performed during break-in
period. Perform these inspections until the first 5000 Km
** Valid only for trucks with Spoke wheel assemblies
*** Failure to tighten U-bolts at suggested intervals may result in spring failure (not covered under warranty)

2015 DRAMIS International inc. All rights reserved

11

Ver 1.0 /22-12-15

3.2 OIL LEVEL CHECK PROCEDURES


Dump body Vehicle must be level and dump body must be completely lowered to check oil level.

DTS HYDRO PNEUMATIC DTS SUSPENSION


DRAMIS uses a maintenance free rear suspension, however it is important to check daily for any apparent damage or oil
leakage.
To check suspension oil level vehicle must be level and suspension must be at Operating Ride Height.
See Operating ride height procedure. SEE SECTION 2.1

2015 DRAMIS International inc. All rights reserved

12

Ver 1.0 /22-12-15

Oil filter specification


The vehicle is equipped with clogging light indicator in the cab. If the warning light indicator turns on, filter must be
replaced immediately. When replacing filter elements be sure to use authorized equivalent if OEM replacement part if not
available. We highly recommend using OEM replacement filter elements.

2 warning lights when there is clogging in dump body return filter as well as suspension pressure and return
filters. Special note about dump body filter light. It is normal that it turns on while body is coming down. This
is caused by backpressure in the system due to high flow and doesnt mean filter is clogged. It indicates filter
clogging when it turns on as soon as PTO is engaged (after successful leveling)

RECOMMENDED FILTERS:
-

Dump body return filter : Microglass element with 5 micron 1000 efficiency and rated for at least 120 gpm flow

Rear suspension pressure filter : Microglass element with 5 micron 1000 efficiency and rated for at least 10 gpm
flow and 5000psi rated pressure
Rear suspension return filter : Microglass element with 7 micron 1000 efficiency and rated for at least 10 gpm
flow

2015 DRAMIS International inc. All rights reserved

13

Ver 1.0 /22-12-15

4. Maintenance
4.1 PREVENTIVE
Service tables
For every sub-system that DRAMIS has added to the base chassis, please refer to recommended service tables. Each table
indicates specific maintenance intervals and requirements. These tables exclude the chassis OEM maintenance & service
schedules.
Inspection check list in order to track maintenance tasks please refer and use the DRAMIS inspection check list for each
maintenance interval. Copy of these check lists must be retained for the first 4000 hours for warranty and repair tracking
of each unit. (Ref. to EQ-00-00 DRAMIS Inspection Check list)
Please follow base preventive maintenance list below in order to maximize life expectancy of all your suspension
components.
Mainly for the front and rear suspensions you need to:

Every week:
o

Apply grease on drive shafts, steering column and U-joint grease points.
Note: There is a multi-point automatic greasing system for all other components (Suspensions,
Dump Body and Axles etc.). See section 8.4
o Check for any excessive or uneven tire wear. Have alignment performed at first signs of excessive or uneven tire
wear. Refer AMS50THD Twin Steer Workshop Manual & alignment guidelines (Section 8.1.4)
Twice per year: Check all steering components with special care for tie rod ends excessive play and obvious damage
to drag links.

4.2. PREDICTIVE
As every site will have different wear based on topography, environment, fuel quality, load and driver behavior we can
issue recommendations as to when to replace components or refurbish/overhaul them. The trucks are designed with an
approximate 25,000 hours life span. This is mainly with regard to the continued stresses and corresponding metal fatigue
that the frames will encounter. Below is an overview of what we believe to be a reasonable predictive maintenance

DRAMIS reserves the right to void any warranty in case of absence and/or lack of
maintenance as well as abusive use including overload above approved GVWR and Payload.
schedule.

2015 DRAMIS International inc. All rights reserved

14

Ver 1.0 /22-12-15

TABLE T1-B Predictive maintenance


INTERVALS (ENGINE
HOURS)

SYSTEM: General maintenance guidelines


Repeat every 4000
hrs

ACTIONS
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Hoses and belts replacement if signs of damage


Brake shoe replacement
Auxiliary diesel heaters refurbishment
Battery replacement
Startermotor replacement
Alternator replacement
Air Dryer replacement
Heated fuel filtration system replacement
Air compressor
Brake cylinder replacement
Slack Adjuster replacement
Gearbox Mounted PTO Replacement
Steering link ball joints replacement
Front Shock absorber replacement
Front spring wear plate replacement
Turbo replacement
Injector replacement
High pressure fuel pump replacement
Water & Hydraulic pumps replacement
Fan Drive, Radiator mounts, Hoses and belts replacement
Cab mounting points replacement
Central lubrification system pump replacement
Steering gears and pumps replacement
Drive shaft refurbishment (Yokes)
Top end engine overhaul
Engine mounts replacement
Gearbox mounts replacement
Dump cylinder replacement
Reaction rod replacement
Front Spring repacking
Drivers seat replacement

8000 12000 15000

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

Warranty Period 4000 engine hours or 2 years from in service date


Based on average 10h/day - 300 hours/ Month - MONTHLY MAINTENANCE CYCLE
Follow OEM Chassis Maintanance rules unless deviating as described
above

2015 DRAMIS International inc. All rights reserved

15

Ver 1.0 /22-12-15

Alignment

5. Front Twin Steer Alignment


Front twin steer axle alignment is required every time a steering component is replaced or an event requiring loosening of axle U-bolts is
performed, and on any of the steering axles.
As noted in the preventive maintenance section, alignment must be performed at first signs of excessive or uneven tire wear.
Important alignment notes:

During alignment procedure, it is important to make sure that the mechanical steering stops are well synchronized between both
axles as well as with the hydraulic assist system relief valve. Bad synchronization of mechanical steering stops is a major cause of premature
wear on steering components and may potentially result in the failure of critical parts to the safe operation of the vehicle.

During alignment procedure, all tires, (front and rear) must be on the same level so that the twin steer equalizer beam is in a level position
(see drawing). Use blocks when needed. Failure to follow this requirement will result in bad alignment that could potentially cause premature
tire wear and erratic vehicle behavior. The above also applies when using turn-tables that are integrated in the floor under one of the two
axles.

Please refer to Workshop manual for complete information on maintenance of AMS50THD Section 8.1

2015 DRAMIS International inc. All rights reserved

16

Ver 1.0 /06-10-15

6. Trouble shooting
Product ID
AMS50THD
TWIN STEER

Trouble

Diagnostic

Solution

Not working
Not working
Not working /
Malfunction

Warning light is ON.


Oil level to low. (Warning light is ON)

Malfunction

Noisy hydraulic pump or damaged.

Not working

Burned fuse.

Call DRAMIS After Sales Service.


Add oil (Mobil UNIVIS HVI 26)
Tighten or replace damaged hose /
coupling.
Check if restriction in suction hose
otherwise Call DRAMIS After Sales
Service.
Replace fuse If it burns again call
DRAMIS After Sales Service.

Hydraulic leak / hose failure.

DTS Hydro
Pneumatic
Suspension
Not working

Improper rear sensor adjustment.

Not working

Fault code. (Warning light is on)

Not working

Ground level is over 7 degrees when dumping.

Malfunction

Contaminant in height or pump control manifold.

Malfunction

Oil level to low.

Malfunction

Dump body is overloaded.


Dump body position, improper proximity switches
adjustment.

Malfunction
Not working
Dump body &
Telescopic
cylinder

Ground level is over 7 degrees when dumping.

Malfunction
Hydraulic pump.
Not working
Not working

Contaminant in hydraulic circuit.

Malfunction
Not working
Not working

Telescopic cylinder.
Spool valve malfunction.

2015 DRAMIS International inc. All rights reserved

17

Whenever one of the following


components (DTS pump and
suspension manifolds, DTS pump, DTS
ECM, DTS height or level sensors) are
changed, system calibration is
required. Please contact Simard I
order to get Commissioning DTS
procedure and determine what steps
of that procedure need to be
performed depending on components
changed.
Check oil level or Call DRAMIS After Sales
Service.
Move vehicle to proper level 7degrees or
less.
Clean circuit and components and replace
oil filters.
Add oil Univis HVI 26Shell Tellus 32 or
Chevron AW32
Reduce weight in Dump body.
Adjust sensor See adjustment
procedure PENDING
Move vehicle to proper level 7degrees or
less.
Check if hydraulic tank is pressurized
between 3-5 PSI
Check if there is any restriction in suction
hose and/or valves.
Clean circuit and components and replace
oil filters.
Check for any hydraulic leaks.
Check for oil leak or if any damage on
cylinder.
Check for any obstruction in air system.

Ver 1.0 /22-12-15

Malfunction

Automatic Tail gate system.

Make sure that air pressure is at least 70


PSI or more.
Cables tensions have to be the same.
Tension on door swivel must be identical
Check if both cables are attached with
cable clamps. There must be equal

tension between automatic door


cables on each side

Not working
Automatic
Greasing
system
On Board
Scale
Truck
Vibrator

Refer to Schedule 12.5


Refer to Schedule 12.6
Refer to Schedule 12.7

2015 DRAMIS International inc. All rights reserved

18

Ver 1.0 /22-12-15

WARRANTY

WARRANTY
DRAMIS comprehensive warranty covers 4,000 engine hours or 2 years whichever comes first.
This assumes execution of recommended preventive maintenance actions (Daily and other recommended
maintenance intervals included in service tables).

All DRAMIS Manufactured components are warrantied against manufacturing defects.


All non DRAMIS components are covered under original OEM warranties if not included under the
0-4000hours/ 2 year warranty
Customer must claim warranty to authorized dealer or directly to DRAMIS. Refer to EQ.03XX_D55T Service / Warranty Claim document
DRAMIS Customer must supply maintenance reports (EQ-00-00 D55T Inspection check list)
confirming that preventive maintenance activities have been performed in proper time and fashion.

Warranty excludes Tires, lubricants, Dump body liner and other consumables as well as wear part
replacement (Clutch, Brake Pads, Brake Drums, paint and upholstery). This assumes payload behavior
adherence to our 10/10/20 rules. Customer must supply payload reporting to Dealer and DRAMIS for
warranty coverage and claims.

10/10/20 Rules

Proper payload management is not only important to the health of your equipment, but to the health and
safety of your employees. Thats why it is important to understand the 10/10/20 ruleand to follow it.
The rule states, No more than 10 percent of payloads may exceed 1.1 times the trucks target payload and
no single payload shall ever exceed 1.2 times the maximum target payload.

Another way to look at it is that no more than 10 percent of loads may exceed 10 percent over target payload and no
loads may exceed 20 percent over target payload.

The 20 percent never to exceed is for the safety of the operator. When you exceed target payload plus 20
percent you have exceeded the steering and braking certification of the truck.
Loads in excess of 20 percent over recommended payload should be dumped immediately.

The mean (average) of the payload distribution shall not exceed the target payload
PAYLOAD

WARRANTY

< 55 METRIC
TONS

YES

+ 10% = between 55 m.t. to 60.5 m.t


Only one load higher than 55 m.t. but not
greater than 60.5 m.t out of ten loads is
acceptable.

IF >60.5
METRIC TONS

If > 66 METRIC TONS (=+20% OVERLOAD)


once

YES FOR 10% OF TIME


IF 10 LOADS PER SHIFT; 1 LOAD AT between 55
and 60.5 PER SHIFT IS ACCEPTED UNDER
WARRANTY COVERAGE

VOID

VOIDS ALL WARRANTY ON ALL SYSTEMS

2015 DRAMIS International inc. All rights reserved

19

Ver 1.0 /06-10-15

Warranty coverages

DRAMIS
WARRANTY
COVERAGE
Front Twin
Steer
Suspension
(AMS50THD)
Rear Hydro
Pneumatic
Suspension
(DTS)
HD DUMP
BODY
Body Only
G2
Telescopic
Hoist
AutoGreasing
System
On Board
Scale
Truck
Vibrator

OEM

MONTHS

ENGINE
HOURS

PARTS

SHOP
WORK

Simard
Suspensions

24

4000

100%

100%

Simard
Suspensions
& VSE

24

4000

100%

100%

Dramis

24

4000

100%

100%

Bibeau
Mailhot

12
24

n/a
n/a

100%
100%

Workmanship defects
Manufacturing defects
and materials

Groeneveld

12

n/a

100%

See OEM manual

Air-Weigh

36

n/a

100%

See OEM manual

Cougar

12

n/a

100%

See OEM manual

2015 DRAMIS International inc. All rights reserved

20

NOTES

Ver 1.0 /22-12-15