L1061 - Trailer Axles Service Procedures
Contents
1. CI Check lining wear and estimate replacement time replace with new shoes or reline when thickness of lining is inch at thinnest point or inch about rivet or bolt head and replace any cracked broken or oil soaked linings immediately Inspect camshaft camshaft spider bushing and camshaft support bracket bushing for any signs of wear CI Lubricate camshaft bushings and brake adjusters Inspect brake drums for heat checks grooves hot spots glazing cracks and out of round L1061 100 000 MILES ONCE A YEAR OR AT BRAKE RELINE J Replace wheel bearing lubricating oil if applicable CI Check brake air chambers and slack adjusters CI Inspect brake rollers roller shafts anchor pins and bushings and replace if necessary CI Lubricate camshaft bushings and brake adjusters CI Check shoes for bent shoe ribs cracks in shoe table welds or ribs and elongated rivet holes Replace shoes if any of these conditions exist Trailer Suspension Systems 250 Chrysler Drive Unit 3 Brampton ON Canada 165 6B6 905 789 1030 Fax 905 789 1033 L1061 1 09 www hendrickson intl com HHENDRICKSUN Trailer Suspension Systems 866 RIDEAIR 743 3247 2070 Industrial Place SE 330 489 0045 Canton OH 44707 2641 USA Fax 800 696 4416 Information contained in this literature was accurate at the time of publication Product changes may have been made after the copyright date that are not reflected 2009 Hendrickson USA L L C2. U S Rights Hendrickson International Corporation Rights Outside U S All Rights Reserved Trailer Suspension Systems Av Industria Automortriz 200 Parque Industrial Stiva Aeropuerto Apodaca N L M xico 66600 52 81 8288 1300 Fax 52 81 8288 1301 Printed in United States of America
3. bushing and camshaft seals into the spider NWARNING WHEN INSTALLING CAMSHAFT SEALS THE SEAL ON THE SLACK ADJUSTER SIDE SHOULD BE INSTALLED WITH SEAL FACING INTO SPIDER THIS ALLOWS GREASE TO PURGE OUTSIDE THE BRAKE ASSEMBLY WHEN GREASING THE CAMSHAFT BUSHING FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE GREASE TO COME INTO CONTACT WITH BRAKE LININGS CAUSING BRAKE FAILURE Install cam roller assemblies onto the brake shoes Install the camshaft into the spider Install spacer washer and lock ring on cam before sliding the cam through the camshaft support bracket Install the slack adjuster and the lock ring L1061 H HENDRICKSON TRAILER AXLE SERVICE PROCEDURES N WARNING WHEN REASSEMBLING BRAKES HENDRICKSON RECOMMENDS THAT THE BRAKE RETURN SPRINGS BE REPLACED WITH NEW SPRINGS TO ASSURE PROPER OPERATION OF THE BRAKE 4 nstall the brake return springs on the brake shoes 5 Position brake shoes on the spider and insert the anchor pins 6 If air brake chambers are replaced the correct mounting holes must be used 10 correspond brake adjuster length see figure 8 6 B RAKE ADJUSTER 5 1 2 BRAKE ADJUSTER A B H OLES 5 B RAKE ADJUSTER B B OLEs Figure 8 7 Connect slack adjuster to brake chamber pushrod 8 Adjust brakes as outlined in brake adjustment procedures NOTE To ensure brakes meet F M V S S 121 performance requirements Hendrickson recommends that onl
4. extreme care must be exercised obtain their correct location and to ensure the spring seated load bearing surfaces are parallel to each other Any welding of additional attachments to the axle should be approved by the Hendrickson trailer product engineering department to maintain warranty coverage It is necessary when welding to avoid the high stress areas on the tube top compression zone and tube bottom tension zone All welds should be made as close to horizontal centerline as possible When ihe axle tube is subjected heat from welding and then rapid cooling the material adjacent the weld loses its desirable ductile properties and becomes brittle If this condition exists in the high stress areas under maximum load conditions the life of the axle will be greatly reduced and premature fatigue failure can occur Recommended locations for the welds are shown below in figure 5 Weld placement recommendations for suspension bracketry No WELD ZONE 3 00 Max 2 00 M AX 1 50 pg 4 00 No WELD ZONE The welding rods should conform to American Welding Society AWS grade E 7018 Oven dried or comparable Recommended rod size is 282 inch at voltage and amperage recommended by the electrode manufacturer For maximum strength a three pass weld should be used L1061 The arc should not be broken at the end of each pass and the corners should be wrapped The electrode should be b
5. 2nd Digit P ConMet PreSet 2nd Digit Dash No RTR or 1 yr Std Service 2nd Digit Dash No Drums 3rd Digit C Cast Drum 3rd Digit F Fused Drum 3rd Digit 315 3 spoke 15 wheel all 3 Digits 520 5 spoke 20 wheel all 3 Digits 622 6 spoke 22 wheel all 3 Digits 624 6 spoke 24 wheel all 3 Digits RTR Lube G Grease F Syn Semi Fluid Grease O 80 90 Oil S SAE 50 Dash None Dust Shields D Dust Shield Included Dash None L1061 H HENDRICKSON TRAILER AXLE SERVICE PROCEDURES AXLE INSTALLATION To ensure safe operation and maximum durability TOP CENTER HOLE on parts such as brakes linings and tires it is necessary to position and install the axle properly It is recommended that the axle assembly be installed so the cams rotate in the same direction as the wheels see figure 2 WHEEL ROTATION AXLE TOP CENTER _ HOLE CENTERLINE gt Figure 3 Cam and wheels rotate in the same direction AM AXLE REPAIR Installation in which the camshaft rotation is opposite A WARNING ANY AXLE FOUND WITH CRACKS that of the wheel rotation could cause noisy brakes SHOULD NOT BE REPAIRED BUT chatter and wheel hop With This is mind the axle REPLACED IMMEDIATELY REPAIR should be ordered with the placement of air chamber WELDING CAN BE DETRIMENTAL TO and slack adjuster assemblies that will ensure the THE STRUCTURAL INTEGRITY OF THE correct direction
6. 5 Figure Gas Metal Arc ER70S X 5 18 solid Gas Tungsten Arc ER7O X A5 18 NOTE For maximum strength a three pass weld TIG has non consumable should be used All final welds should be electrode use stick electrodes made in one continuous pass The arc should Flux Cored Arc 7 5 20 not be broken at the end of each pass and the self shielded wire corners should be wrapped WELDING HARDWARE TO AXLE NOTE TO PREVENT AXLE DISTORTION N CAUTION axle installer should obtain e Alternate welds between the front and rear of and read a copy of the suspension ihe bracket manufacturer s installation instructions e Alternate welds between the roadside bracket and curbside bracket e Only use operators certified by AWS This welding recommendation pertains to all Hendrickson tubular axles Unapproved variation e The axle and its mating bracket from the procedures listed will void the axle warranty must be 60 degrees minimum and could result in an unsafe weld In the case of and free of moisture dirt scale an uncertain circumstance the Hendrickson Trailer paint and grease Do not bring in Products Engineering Department should be axles from non heated storage and contacted at 1 800 RIDEAIR 743 3247 weld while cold e Prevent bearing damage When grounding welding equipment to the axle prevent current from passing through the wheel bearings TACK WELDING BRACKET TO AXLE N
7. LOCKING UP OR COMING OFF DURING VEHICLE OPERATION NWARNING L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES GREASE LUBRICATED WHEEL ENDS Grease should be replaced if contaminated or if the hub is removed from the spindle For normal service grease should be replaced annually or at 100 000 mile intervals For severe or off highway service grease should be replaced semi annually or at 30 000 mile intervals Bearings should be packed by machine or by hand methods to ensure grease is forced into the cavities between The rollers cone and cage of the bearings The wheel and hub cap should be filled with grease when reassembling SUGGESTED GREASE PROPERTIES The table below recommends the NLGI 2 grade of grease under normal loading and operating speeds of 100 1000 rpm For heavy loads and low speeds ihe advice of a lubrication engineer should be obtained GREASE GUIDE SOAP BASED NLGI GREASE GREASE TYPE GRADE NOTE Calcium Complex 1 Use in Extreme Cold Lithium Complex 2 Normally Preferred SEMI FLUID NLGI SYNTHETIC GREASE GREASE TYPE GRADE NOTE Mobilith 007 00 Normally Preferred or equivalent NWARNING DO NOT MIX LITHIUM CALCIUM SODIUM OR BARIUM COMPLEX GREASES DUE TO POSSIBLE COMPATIBILITY PROBLEMS WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER IT IS NECESSARY TO ENSURE THAT ALL THE OLD GREASE HAS BEEN REMOVED HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H WHEEL BEARING ADJUSTMENT PROCEDUR
8. Weld on Spider T Torque Plate for Air Disc Brake Brake Type B B Lock S Single Anchor Pin SAP Service Only F Std Service Dual Anchor Pin DAP P Pin Style X HXS XLII Dual Anchor Pin DAP D Air Disc Brake Dash No Brake Shoes Brake Size 1250 121 4 x 5 Brakes 1255 121 4 x 51 2 Brakes 1274 12 4 x 712 Brakes 1585 15 85 8 Brakes 1650 1616 x 5 Brakes 1670 161 0 x 7 Brakes 1685 1617 85 s Brakes 1610 161 2 x 10 Brakes 1870 18 x 7 Brakes 2080 20 x 8 Brakes 430 430mm Air Disc 16N 162 Spider Only 15N 15 Spider Only 12N 12 4 Spider Only 4 Dashes No Brakes Cam Length S Std Short Length 17 s M Std Medium Length 20 8 L Std Long Length 233 4 X Special Length Non Std Dash No S Cams Cam Option C Cam Tube B RM Cartridge Bushing Dash No Special Cam Options ABS Option B ABS Mounting Bracket Only ABS Sensor Installed Dash No ABS Sensors Brackets Brake Adjusters B Bendix G Gunite H Haldex Dash No Brake Adjusters Chambers Bendix H Haldex M MGM K Knorr Air Disc Brake Only Dash No Chambers RTR Packages 1 10 stud hub piloted 1st Digit 6 6 stud hub piloted 1st Digit 8 stud hub piloted 1st Digit Dash No Hubs Ist Digit V HVS 3 yr 2nd Digit L HLS 5 yr 2nd Digit U HUS 7
9. e 24 Drive axle Truck spindle 1586 15 X 8 165 162 X 5 SHOE TYPE 166 16 2 X 6 e CS Cast shoe e 167 1617 X 7 e FB Fabricated bolted lining 1680 16 2 X 8 e FC Fast change fabricated e 1686 16 2 X 8 FCXX Fast change Xtra Life II 1610 16 2 X 10 e FT Fabricated tapered 187 18 7 e N No brakes flanges spiders e 208 20 X8 e NBW No brakes with spiders e NB No brakes with flanges SPIDER TYPE ADB Air disc brakes e Bolt on e F Flanges only for bolt on e W Weld WHEEL END TYPE NH No hub wheel W Cast spoke wheel WD Cast spoke wheel and drum B6 6 stud 8 4 BC hubs B8 8 stud 6 2 BC hubs 10 stud 11 BC hubs 10 stud 13 e BC hubs B18 10 stud 8 A BC hubs SW6 6 stud 834 BC hubs SW8 8 stud 6 BC hubs SW10 10 stud 11 4 BC hubs AIR CHAMBER e A Air chambers mounted on axle L1061 TRLAXLE MODEL NUMBERS In June 2008 Hendrickson announced the implementation of a new configuration system for nonintegrated trailer axles called TRLAXLE Your Customer service representative will be able to create a TRLAXLE model number and provide a price on most HN D22 and HP P22 axles when you send in your completed Axle Ordering Guide 1964 or Electronic Axle Ordering Guide E964 Other specialty axles drop or raised center axles A45 A65 K22 K30 010 021 and T24 will continue
10. grease from the axle spindle Install the sensor block on the fixture fool and attach the fixture tool to the axle spindle Adjust the position of the fixture tool as necessary fo align the sensor block to the scribed position in step 2 and tighten in place Weld the sensor block to the spindle axle weld along both sides of the block see Figure 10 Remove the fixture tool and let the sensor block cool after cool down install the sensor spring clip and sensor as illustrated in Figure 11 L1061 H HENDRICKSON TRAILER AXLE SERVICE PROCEDURES TORQUE SPECIFICATIONS FASTENER SPECIFICATIONS PART NAME SIZE amp THREAD TORQUE Spindle Nut 2 5 16UN 250 400 ff Ibs Cam Brackets 5 16 18 Self tapping 175 225 in Ibs Air Chamber 5 5 11 UNC 100 i j Mounting Bolts Dust Shield self tapping 180 200 in Ibs Mounting Brake Lining Brass Screw 100 150 in 8 To Table 3 3 24UNF Hub Cap to Hub ha 20UNC 96 144 ff Ibs 5 16 18 UNC 144 216 in Ibs Wheel Stud 3 4 16UNF 175 200i 155 Backnut 7 8 14 UNF 180 250 ft Ibs 1 14 UNF 200 300 ft Ibs Haldex ABA he 14 UN 40 50 ft Ibs Control Arm Nut SUGGESTED PREVENTATIVE MAINTENANCE EVERY 1 000 MILES CI Check oil level in wheel hub and inspect wheel for leaks 15 000 MILES OR MINIMUM OF TWICE A YEAR J Check brake adjustment CI Repack wheel bearings grease application 25 000 TO 30 000 MILES
11. manufacturer criteria for serviceability 3 Check tires for proper inflation and matching diameters 4 Parkthe trailer on a smooth and level pad with ihe parking brakes released NOTE After backing the trailer in pull it forward feet to a gentle stop This will allow suspension parts to settle in a forward running position Use wheel chocks to prevent injury due to accidental movement of the trailer With the brakes still released adjust the height control valve for the proper setting and the upper coupler to the proper height by raising or lowering the landing gear legs 6 DO NOT proceed unless the wheel bearing end play is known fo be in adjustment per TMC the bearing manufacturer and or this manual Il SPECIFICATIONS Axle alignment specifications may be stated in inches degrees minutes of angle MOA or 1 60th of a degree or m M Each format can produce equivalent results Hendrickson Trailer Axles are built to less than 2 5 MOA run out at each spindle TOE IN TOE OUT Installed axles should measure no more than 8 MOA toe in and 4 toe out RECOMMENDED ALIGNMENT SPECIFICATIONS Remove tire 1 8 D 0 Remove lire Figure 4 ALIGNMENT Axles should be adjusted to an alignment of no more than 5 MOA scrub with the true center of the trailer frame if it is a single axle If the trailer has multiple axles each axle should be adjusted to not more than 2 5 MOA s
12. E DOUBLE NUT ARRANGEMENT 1 Prior to installing any wheel end fasteners make sure the spindle area is free of dirt and debris As well make sure all nuts and washers are free of dirt Clean mating surfaces are important for proper wheel end assembly 2 After properly installing the bearing cones and wheel end seal onto the spindle and Sliding the wheel end onto the spindle tighten the inner spindle nut with a torque wrench to 150 200 ff Ibs set the bearings and wheel end NCAUTION Do not use an air impact wrench to tighten this nut 3 Loosen this inner nut fo allow the brake drum to rotate freely Backing off one 1 full turn 15 recommended 4 Retighten the inner spindle nut to 50 ff Ibs by hand using a torque wrench to position the bearings for final adjustment NCAUTION Do not use an air impact wrench to tighten this nut 5 Back the inner spindled nut off turn 6 Install the retaining fastener or fasteners onto the spindle according the fastener used If washers are used be sure they are facing in the right direction and are clean Make sure any washers with dowels fit properly into the mating holes 7 Install the outer spindle nut Using a torque wrench tighten this nut to 300 400 ff 108 Resulting end play should be 001 to 005 inch NOTE If end play is not 001 fo 005 inch disassemble and repeat this procedure NWARNING FAILURE TO TORQUE THE OUTER LOCK NUT PROPERLY COULD CAU
13. ENTS NWARNING A SERIOUS OR FATAL INJURY CAN OCCUR IF YOU LACK PROPER TRAINING e FAIL TO FOLLOW PROPER PROCEDURES DO NOT USE PROPER TOOLS AND SAFETY EQUIPMENT ASSEMBLE AXLE COMPONENTS IMPROPERLY USE INCOMPATIBLE AXLE COMPONENTS e USE AXLES OR AXLE COMPONENTS IN A NON APPROVED APPLICATION NWARNING THIS MANUAL CONTAINS DETAILED SAFETY INSTRUCTIONS READ UNDERSTAND AND FOLLOW THIS MANUAL e GET PROPER TRAINING e LEARN AND FOLLOW SAFE OPERATING PROCEDURES USE PROPER TOOLS AND SAFETY EQUIPMENT USE PROPER COMPONENTS THAT ARE IN GOOD CONDITION L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES AXLE IDENTIFICATIONS otandard Hendrickson Trailer Axles are available in various spindle and tube combinations and are designed for on highway use Axles are available in straight drop or raised center axles and can be ordered fully dressed with hubs and brake drums as shown in figures Other miscellaneous components such as slack adjusters air chambers cam tubes etc can also be specified Straight Axle Drop center Axle or Raised center axle STANDARD PRODUCT OFFERINGS The part number a description and a serial number are all imprinted on a tag that is attached lo the axle beam center as shown in figure 1 The part number is used to identify the axle specifications This number should be referred to when contacting Hendrickson to determine the appropriate service parts The serial number is used t
14. H TECHNICAL PROCEDURE HENDRICKSON TRAILER AXLES SUBJECT Service Procedures LIT NO 11061 DATE January 2009 TABLE OF CONTENTS INTRODUCTION oreas G95 O 445 0 Oona Ne Dn ee ore oe as 2 SAFETY PRECAUTIONS 2490 3 479308 230820 4 908 8129 598 209 9 E wa w Sw eee shuk s hens 9 O3 897808 RR 3 AXLE IDENTIFICATION 2524 8 009 2395 90 8 Fo 308 8 X RC d 4 AXLE INSTALLATION acude dessen Scd RC kuwa un anode ees Qs cake ween EUER 9 TRAILER AXLE ALIGNMENT a ORAS ES ODE DIC SO 10 GENERAL WELDING RECOMMENDATIONS a BI RR Rh 11 WHEEL BEARINGS usos hee C3 31319 3987881 89 308 OGRE 13 RECOMMENDED BRAKE ADJUSTMENT PROCEDURE n B B B BB 15 BRAKE DISASSEMBLY ASSEMBLY uuseeeeeeeeeeee ee 16 WELDING ABS WHEEL SPEED SENSOR BLOCKS 18 TORQUE SPECIFICATIONS ARUM eos 19 SUGGESTED PREVENTATIVE MAINTENANCE eessenn BR ee 19 HHENDRICKSON gt Z amp Z Rides On ls HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H 022 Benl or Drop Axle INTRODUCTION Hendrickson presents This publication aid in understanding the Hendrickson Trailer Axle and ils application
15. OTE Do not place tack welds at what will be the ends of the final weld Tack weld all brackets onto axle before fusing these tack welds into final welds Thoroughly clean the slag from the tack welds before applying the final welds see figure 7 L1061 12 WHEEL BEARINGS OIL LUBRICATED WHEEL ENDS Oil should be changed at least every 100 000 miles or once year and whenever the seals or brakes are replaced Oil level should be inspected every 1 000 miles Always allow a few minutes after adding oil or vehicle operation for the oil to settle when establishing the required oil level SUGGESTED OIL PROPERTIES Petroleum based or synthetic oils that meet or exceed military specification MIL L 2105D and American Petroleum Institute service classification GL 1 through GL 5 are the minimum requirements for use in Hendrickson Trailer Axles The table below indicates which SAE viscosities are recommended for various temperature ranges the vehicle will encounter SAE 140 SAE 85W 140 SAE 90 SAE 80W 140 SAE 80W SAE 75W 140 SAE 75W 90 SAE 75W C 40 26 12 0 4 415 27 38 C A T n T HT Are v N F 40 15 10 32 40 60 80 100 F Ambient air temperature NWARNING DO NOT MIX MOTOR OIL WITH EP GEAR OIL DUE TO POSSIBLE COMPATIBILITY PROBLEMS FAILURE TO CORRECTLY LUBRICATE BEARINGS AND TO MAINTAIN PROPER LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE WHICH COULD RESULT IN THE WHEEL
16. P and e Brake sizes plus 12 A x 7 12 A x 51 and 121 4 x 5 e Brake lining options In addition to new TRLAXLE model number Hendrickson made the axle description more meaningful Below is guideline for interpreting the new description of your TRLAXLE model number Newly created non configurable axle specs and specialty axles will also adopt this new description logic The following page gives an explanation of all the new axle description codes o e rc Spider Brake Size ABS Oplion Chambers RTR Packages Dust Shields 3 1 c Qo O O O Brake Adjusters HENDRICKSON TRAILER AXLE SERVICE PROCEDURES HENDRICKSON AXLE DESCRIPTION MATRIX Spindle HN Tapered Spindle HP Parallel Spindle Pro Par Type P90 HUS Unitized Axle Type S Straight U Bent C Cambered H Half Stub Tube Size 50 5 Round 56 5 4 Round Tube Wall Nominal 5 5 8 Nominal H 5 8 Nominal Heavy Duty 6 4 Nominal 0 Solid Bar Tire Inflation T HREMAAX or TIMS P MTIS PSI Prepped V Axle Vent Only 3 3 Hole Prep Only M Military Set up Dash None Axle Track Track Length inches Ist Digits it Track Length s 4th Digit Auto Lube L Lube System Fittings Installed Dash None Spider B Spider F Flange Only W
17. SE THE WHEEL TO COME OFF DURING VEHICLE OPERATION WHICH COULD RESULT IN PROPERTY DAMAGE SERIOUS INJURY OR DEATH IF AN EXTERNAL TANG OR SETSCREW TYPE LOCK WASHER IS USED IT IS IMPORTANT TO REMEMBER TO BEND THE TABS OVER THE OUTER LOCK NUT OR TO INSTALL THE SET SCREWS IN THE LOCK WASHER AFTER THE OUTER NUT HAS BEEN TORQUED FAILURE TO FOLLOW THIS PROCEDURE COULD RESULT IN PROPERTY DAMAGE SERIOUS INJURY OR DEATH N WARNING Periodic inspection and regular replacement of lubricant is important to obtain maximum bearing life Always inspect bearings for damage prior to installation When installing wheel bearings it is important to ensure both the inside of the wheel hub and bearings are clean Hendrickson recommends that seals be replaced when wheels are removed Extreme care should be taken when reinstalling wheels to prevent damage to the seals SPECIFICATIONS AXLE LOCATION SPICER BEARING SPICER BEARING INDUSTRY STD INDUSTRY STD WIDTH OUTSIDE INSIDE MODEL CUP NUMBER CONE NUMBER CUP NUMBER CUP NUMBER DIAMETER BORE D22 Inner M10HA102 M10HB100 HM218210 2 18248 ore X S 3 542 D22 212011 212049 1 500 4 813 2 625 P22 MIOHAI16 MIOHBII9 HM518410 HM5 18445 1 563 6 00 ook L1061 ADJUSTMENT PROCEDURE N CAUTION Failure to properly adjust brakes could cause reduced braking performance 1 Grease
18. UIPMENT e DO NOT ATTEMPT TO SAND GRIND CHISEL FILE HAMMER OR ALTER BRAKE LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT e FOLLOW O S H A STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED WHEN WORKING WITH BRAKE MATERIALS IT IS CRITICAL THAT ANY BRAKE DRUM REACHING MAXIMUM WEAR DIAMETER AS CAST ON DRUM BY TURNING GRINDING AND OR WEARING BE CONSIDERED UNSAFE AND IMMEDIATELY REPLACED IN ORDER TO AVOID SERIOUS INJURY OR DEATH ANY BRAKE DRUM EXCEEDING THIS DIMENSION IS CONSIDERED A SAFETY HAZARD IF IN DOUBT CONTACT THE BRAKE DRUM MANUFACTURER BRAKE DISASSEMBLY ASSEMBLY BRAKE DISASSEMBLY 1 Release brakes and back off slack adjuster 2 Remove slack adjuster lock ring and slack adjuster 3 Remove brake drum 4 Remove anchor pins and brake shoes N CAUTION Excessive pounding on anchor pins or cam roller pins to remove or install them can damage the pins and cause misalignment of the brake spiders and brake shoes The use of a soft hammer or brass drift is recommended to remove or install the anchor pins 16 9 6 Remove brake return springs Remove camshaft lock ring spacer washer and cam shaft Remove cam roller and shaft in case of the cast shoe remove roller shaft set screw and roller assembly and anchor pin bushing from shoes Remove anchor pin bushings camshaft bushing and seals from spider BRAKE ASSEMBLY 1 Install new anchor bushings camshaft
19. acked up to fill in the filler crater at the end of each pass Thoroughly clean the weld between each pass NCAUTION Do not bring axles in from non heated storage and weld while cold NCAUTION To provide optimum suspension to tube welds preheating is recommended Preheating will minimize loss of ductile properties in the weld area by slowing the rate of cooling thus reducing the formation of an untempered martensitic grain structure adjacent to the weld Martensite a brittle grain structure is formed by the rapid cooling of the metal surrounding the weld area Preheat the suspension seat weld area to 500 to 600 Fahrenheit with rosebud prior to welding Preheat temperature should be verified with temperature sensitive crayon or other appropriate means NCAUTION not test the arc on the axle beam HARDWARE FIT Avoid excessive welding Fit the seat hardware as close as possible to axle The gap should exceed s inch see Figure 6 1 8 M Ax INCORRECT CORRECT Figure 6 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H WELDING METHODS Table 1 lists four methods that may be used to weld Noack 1 Tack weld hardware fo trailer axles The weld tensile strength weet must be 70 000 psi per AWS specifications TABLE 1 each side the ends METHOD FOR WELDING CARBON AND LOW AWS ELECTRODE AWS ALLOY STEELS CLASSIFICATION SPEC Shielded Metal Arc E7OXX Abd 1 stick electrodes A5
20. al rotation of the cams when the axle AXLE BEAM WHERE THE BENEFIT OF 5 Installed THE ORIGINAL TUBE HEAT TREATMENT MAY BE NULLIFIED BY Unless otherwise specified by ihe customer THE WELDING AN AXLE SHAFT Hendrickson Trailer Axles are manufactured without WEAKENED BY WELDING COULD camber If ihe axle is cambered the top dead center FAIL AND CAUSE AN ACCIDENT of the axle will have a small die mark on each end of WHICH COULD RESULT IN SERIOUS the axle close to the inboard side of the brake spider INJURY OR DEATH see figure 3 NOTE Cambered axles must be installed with the die marks in the top center center position It is the responsibility of the axle installer to adjust the brakes properly See the recommended brake adjustment procedure covered in this manual L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H TRAILER AXLE ALIGNMENT Proper preparation is must for effective axle alignment The vehicle tools equipment and work site must all be appropriate for axle alignment The process also requires a trained technician using the correct specifications I VEHICLE PREPARATION American Trucking Associations Technology and Maintenance Council TMC RP 708 Trailer Axle Alignment addresses all the steps needed make ihe trailer ready for alignment To review these 1 Inspect the suspension and axles for any obvious damage 2 Tighten repair or replace as needed any parts that do not meet suspension or axle
21. cam bracket and spider fittings prior to brake shoe installation N WARNING CARE MUST BE EXERCISED TO PREVENT GREASE SPACING FROM COMING IN CONTACT WITH BRAKE LININGS WHICH COULD CAUSE A REDUCTION IN BRAKING PERFORMANCE REDUCED BRAKING PERFORMANCE COULD CAUSE AN ACCIDENT RESULTING IN SERIOUS INJURY OR DEATH 2 Adjust the brake adjuster until the brake lining comes into contact with the brake drum A For green brakes there should be a slight amount of wheel drag at initial adjustment to compensate for any lining irregularities high spots etc A green brake is an unground unburnished brake There is a break in period where the lining will seat into a normal contact pattern with the drum B For burnished or broken in brakes back off the slack adjuster to achieve 010 inch clearance between drum and shoe 3 Apply brakes using normal truck operating pressure average line pressure should be 90 psi NWARNING USE OF AIR PRESSURE EXCESS OF 130 PSI COULD RESULT IN FAILURE OF THE AIR CHAMBER OR SPRING BRAKE CHAMBER WHICH COULD RESULT IN SERIOUS INJURY OR DEATH A Check the amount of push rod travel Maximum should not exceed 2 inches for Type 30 long stroke chambers 2 inches for Type 30 chambers and 1 4 inches for Type 24 chambers L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES a Optimum pushrod travel on green brake should be under 2 inches b Optimum pushrod travel on q burnished or broke
22. crub relative to the front or reference axle This adjustment was previously stated as a difference of not more than inch between the right and leff centers of adjacent angles CAMBER Typical trailer axles exhibit 23 29 MOA of TOTAL camber change from an off ground free state fo a fully loaded condition Cambered axles are engineered flex to a straight beam under load New Hendrickson Trailer Axles may be cambered by special order with 33 MOA of positive camber This allows the vertical axis through the tire to return fo near plumb condition when loaded III ADJUSTMENTS All fasteners should be loosened prior to measure ments and adjustments This reduces disturbances to the measuring equipment All adjustments to axle alignment should be made by first moving the axle toward the rear or the trailer past the intended point This step assures that any free motion in the system is placed in a draft condition Repeated difficulty in adjusting the axle to the desired reading is most offen due a loose wheel bearing badly worn suspension component or a combination NWARNING NEVER BEND THE AXLE BY ANY MEANS IN ORDER TO CORRECT ANY ALIGNMENT CONDITION THIS COULD WEAKEN THE AXLE AND CAUSE AXLE FAILURE WHICH COULD RESULT IN SERIOUS INJURY OR DEATH L1061 H HENDRICKSON TRAILER AXLE SERVICE PROCEDURES GENERAL WELDING RECOMMENDATIONS In welding suspension component parts Hendrickson Trailer Axle
23. n in brake should be under 13 4 inches B Check the angle between the brake adjuster and pushrod With the brakes applied the angle should be 90 degrees 5 degrees N CAUTION When automatic brake adjusters are used it is necessary to follow the installation and adjustment procedure recommended by the automatic brake adjuster manufacturer Failure to follow the recommended procedure could result in improper operation of the automatic slack adjuster resulting in reduced brake performance or premature lining wear For burnished brakes apply pressure to brakes and check for lining to drum contact Using a 010 inch feeler gauge ihe lining to drum contact should range from 60 to 100 percent during brake application D Check to ensure the lining is inside the drum during application More than 060 inch protruding out of the drum 18 recommended 4 Rapidly release air pressure from the brakes and confirm that all brakes quickly release to the normal relaxed position WARNING LININGS CONTAIN NON ASBESTOS FIBERS e BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM e AVOID CREATING DUST DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT HENDRICKSON TRAILER SERVICE PROCEDURES H N WARNING e DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT e DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQ
24. o identify q particular axle along with all of the component parts as specified by the customer at the time of order The axle description serves as a generic description of the axle assembly and can be used determine some specific axle configuration parameters Axle IDelag w EE 1 11061 H HENDRICKSON TRAILER AXLE SERVICE PROCEDURES INTERPRETING TRAILER AXLE PART NUMBERS Axle Model and Spindle Type Axle Type Wall Thickness AXLE MODEL AND SPINDLE TYPE A45 Tapered spindle solid bar A65 Tapered spindle solid bar D10 Tapered spindle D22 HN Tapered spindle K22 Tapered spindle press up 522 Tapered spindle solid bar K30 Tapered spindle press up 990 Tapered spindle solid bar P22 HP Proper style spindle 124 Drive axle Truck spindle AXLE TYPE e AX Straight axle e AU Bent tube drop center axle e AD Straight axle air disc brake WALL THICKNESS e Stub axle an axle cut in half right e 2 Stub axle an axle cut in half left e 3 Stub axle an axle cut in half ambidextrous e 5 wall thickness 5 00 OD e 6 wall thickness 5 00 OD e 7 35 4 wall thickness 5 00 OD e 8 Solid bar SEVENTH DIGIT e Q Standard trailer axle iPAC suspension axle no longer used 2 AdVANiage suspension axle 5 Nominal 2 wall stub axle 6 Nominal s wall stub axle 7 Nominal 9 4 wall stub axle 8 Machined from solid bar stub a
25. requirements Hendrickson Trailer Axles are engineered to meet the demanding requirements of the industry and incorporate the latest design and manufacturing fechnologies This manual is provided to help maintain the safety dependability and performance designed into Hendrickson trailer products Read this manual carefully before you perform installation or maintenance procedures You will find DANGER WARNING CAUTION and NOTE symbols and statements throughout this manual NDANGER INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH NWARNING INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH NCAUTION Indicates hazards or unsafe practices which could result in damage to machine or minor personal injury NOTE Indicates that you must do something in order for the axle or brake to function properly If you have any questions about this manual or its instructions contact Hendrickson Trailer Suspension systems at 1 866 RIDEAIR 743 3247 L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES SAFETY PRECAUTIONS NWARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIR WORK REQUIRING RAISING OF VEHICLE ENSURE VEHICLE IS PROPERLY SUPPORTED WITH LIFT STANDS OF SUFFICIENT RATED CAPACITY DO NOT RELY ON JACKS ALONE FOR SUPPORT OF VEHICLE NWARNING SAFETY GLASSES SHOULD BE WORN AT ALL TIMES WHEN ASSEMBLING OR DISASSEMBLING AXLES AND THEIR COMPON
26. to use their current model number des ignations like D22AU603A2 2 or 22 2 Most HN and HP axle specs will be converted to new IRLAXLE model numbers In most cases the TRLAXLE bill of material will be identical to the D22 or P22 except with following component changes if applicable Sfemco Guardian or Voyager will be the standard seal replacing Chicago Rawhide Abex 3030 19 brake lining will become the standard brake lining Spicer Silver Supreme and Haldex brake linings are being discontinued e Hendrickson s patented axle filter will become standard on all axles New configurations will require specifying 1 Slacks only 2 both slacks and chambers or 3 neither slacks or chambers we cannot configure chambers only e ABS sensors on drum brake specs will be 90 degrees not straight e ABS sensors on air disc brake specs will be straight not 90 degrees e Castellated nuts will not be configurable and must be ordered separately G Model Number TRLAXLE 1 DESCRIPTION HN S em Tube Size Jg Tube Wall Axle Track Auto Lube L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES In general the TRLAXLE product will allow all of the same standards and options currently available on INTRAAX such as Hendrickson proprietary wheel end packages HVS 8 year limited warranty HLS 5 year limited warranty and HUS 7 year limited warranty e TIREMAAX C
27. xle H 5 s HD wall L1061 Application Specific Wheel End Configuration Seventh Digit WHEEL END CONFIGURATION e 0 With spider flanges no brakes hubs or drums e With brakes hubs and drums e 2 With spiders flanges and hubs no brake drums 3 With brakes no hubs or drums e 4 With hubs no spiders flanges or brakes e 5 No spiders flanges brakes hubs drums NINTH DIGIT e A Assemble to order options are picked at the time of placing the axle order Options include brake shoe lining ABS sensor installation and brand selection Assemble order options are for double anchor pin DAP axles only TENTH DIGIT UP e Axle specific Numbers are sequential and are used to record the bill of material for each axle HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H INTERPRETING TRAILER AXLE DESCRIPTORS Axle Model and Spindle Air Chamber Brake Shoe Type Wheel end Type Brake Size opider Type AXLE MODEL AND SPINDLE TYPE BRAKE SIZE A45 Tapered spindle solid bar e 123 1214 X 3 A65 Tapered spindle solid bar 1235 12 e e D10 Tapered spindle 1250 12 4 X 5 e D22 HN Tapered spindle 1255 12 X 5 2 K22 Tapered spindle press up 1275 12 71 e 522 Tapered spindle solid bar e 53 15 X 3 e K30 Tapered spindle press up e 154 15 X4 e 530 Tapered spindle solid bar e 55 ID X 5 P22 HP Proper style spindle e 5 15 X 7
28. y original equipment brake components be used Any questions or comments on the above procedure should be directed to the Hendrickson trailer engineering department L1061 HENDRICKSON TRAILER AXLE SERVICE PROCEDURES H WELDING ABS WHEEL SPEED SENSOR BLOCKS MOUNT SENSOR BLOCK IN THIS SENSOR BLOCK SENSOR BLOCK SPRING CLIP SPRING CLIP TAB B SPEED SENSOR Figure 11 Correct installation of the speed sensor blocks is extremely important for proper operation of the anti lock system Use electric welding equipment only to install the blocks 1 Properly support the trailer axle using jack stands be sure to provide proper clearance to be able to weld the sensor block on the axle near the tone exciter ring 2 With the hub in place locate the sensor mounting block at the 9 or 3 o clock position on the axle spindle to lessen the effect from axle flexure due to loading see figure 9 manually hold the sensor block in place and scribe its location on the axle spindle see Figures 1O and 12 NOTE The distance of the sensor block from the face of the tone ring teeth must be between 125 inch to 187 inch see figure 12 TONEOR EXCITER RING SPEED SENSOR MOUNTING BLOCK Biock WELD BEAD ALONGBOTHSIDES Figure 10 125 10 187 MOUNTING BLOCK 2 EXCITER RING WELD BEAD Figure 2 Remove hub and bearing assembly and brake assembly from the axle spindle Clean all oil or
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