User manual for tata prima 4928 car carrier application

Prepared by: RAMAN DHIMAN
For any queries pl contact: raman.pgpex12@iimshillong.in
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:
Adjustable nut
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:
Adjustable nut
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
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:
1
st
Code Blink 2
nd
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 representative3 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
Figure 19
Male Connector at the
location of Valve 1 & Valve 2
Female Connector with
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
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 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 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 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 46Figure 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 ChambersFigure 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 53Figure 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
DAILY
40,000
80,000
1,20,000
1,60,000
2,00,000
General
Check if necessary tighten: Mounting of air tanks 80,000
If abnormal wear found on tyre, perform wheel rotation.
Check if necessary tighten: Air line clamps 80,000
Chaeck 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, ASA
Remove 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. 80,000
Check mounting bolts of brake chambers, air tanks hydraulic pipes
and tighten if necessary. 80,000
Conduct brake system routine checks. 80,000
overhaul foundation brakes.
Check brake torque plate mounting bolts and tighten if necessary
AXLES
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. 40,000
Check for wheel hubs play and for noise adjust if required. 40,000
Change oil in rear axle including hubs, drain while hot, clean drain
plug and breather. 80,000
Check 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

Hydraulics
Check the oil level in Power Pack Tank
Electrical motor
SUSPENSION
Check shock absorber & replace if necessary 80,000
OTHERS
ELECTRICALS
Ceck 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.S
Type 18.75 m Car Carrier Trailer
Indica Vista loading 8
Indica loading 8
Nano loading 10
Chassis Details
Engine Cummins ISBe
Clutch
Single plate dry friction type,
Outside dia. Of clutch lining 430
Transmission ZF
Wheel & Tyres 11 R X 20, 16 PR
Wheelbase,mm 3460
Max. Width,mm 2500
Front Overhang,mm 1465
Weight
a) Max. Payload, Kg 20100
b) Chassis Wt. Kg 7200
c) Tare, Kg 12700
d)GVW,Kg 40000
External Dimensions:
Length 16240
Width 2600
Height 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 Frame
1 Stage Hydraulic Cylinder -Open length: 1996 mm, Closed length : 1146 mm
2 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 Spring
with Bronze equalizer bush & rubber torque arm bush
IS 1135, IS 3431
BS 1149, BS 970
En 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 axle
No. 2
Make York NGT Axle
Track, mm 1850
Beam Section, ( WXH) 127 mm round, Seamless round tube
Plate thickness 19
Brake Assembly Brakes India Ltd.
Hub Lubrication Grease
Brakes - S cam type 410 X 220
Drum/Wheel PCD 335
Wheel Rim Fixing Dia. 280.8
Wheel Bolts M 22 X 2.5 ( 10 nos.)
Rated Load 12 ton
Weight of axle, Kg 405
Beam wt. per metre 50.58
Slack Adjuster Auto
Brake Dia. 410
Brakes: At 8.0 Bar
Service Brakes
S-Cam brake system,
7 port Relay Emergency Valve
Lining area 410 X 220
Parking Brake Yes
Type Spring type
Engine Exhaust Brake NA
Service Brake Actuators /
Brake Chambers
Brake Chambers: T 30 - 2 No.
Service Brake Actuators: T 30/30 - 2 No.

Brake Actuation
Supply 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 Pin
2" Bolted, 8 Bolts M12, Max rating 102 kN
IS 6763
Material: 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

User manual for tata prima 4928 car carrier application

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