L64 - Welding Procedures

L64 - Welding Procedures
Technical
PROCEDURE
Trailer Suspension Systems

SUBJECT:Welding Procedures

LIT NO: L64
DATE: February 2016
REVISION: G
Welding Procedures 
TABLE OF CONTENTS
Conventions Applied In This Document.................................................................................................... 3
Explanation of Signal Words.............................................................................................................. 3
Links............................................................................................................................................... 3
General Service Notes............................................................................................................................ 3
During Service:................................................................................................................................. 3
Important Safety Notices.................................................................................................................... 3
Contacting Hendrickson.......................................................................................................................... 5
Literature.............................................................................................................................................. 5
Recommended Welding Practices........................................................................................................... 6
Welding Parameters.......................................................................................................................... 6
Welding Area Preparations................................................................................................................. 6
Welding Symbols.............................................................................................................................. 7
Suspension Beam to Axle Weld Parameters
(HT™ Series Suspensions Only)............................................................................................................. 8
Suspension Beam And Axle Setup....................................................................................................... 8
Suspension to Axle Weld Procedure.................................................................................................... 8
Axle Weld Hammer Peening............................................................................................................. 12
Wide Frame Bracket Welding Procedures.............................................................................................. 13
C-Channel Welding Procedures............................................................................................................ 16
Frame Bracket Gusset Welding Procedure............................................................................................. 17
INTRAAX® Suspension Air Spring Mounting Plate Welding Procedures.................................................... 18
HT™ Series Suspension Air Spring Mounting Plate Weld....................................................................... 19
HT™ Series Y-Beam Suspension Bushing Tube Welding........................................................................ 21
Welding Bushing Tube Sleeves......................................................................................................... 21
Welding Bushing Tube Assemblies.................................................................................................... 22
Welded Collar Pivot Connection........................................................................................................... 22
Rebound Limiter Option........................................................................................................................ 22
Attaching Rear Shock Clevis................................................................................................................. 22
HT™ Series Remote Shock Clevis..................................................................................................... 23
Welding Tank Brackets To Slider Box.................................................................................................... 23
Welding to Galvanized Steel................................................................................................................. 24
2
L64 G
Welding Procedures
CONVENTIONS APPLIED IN THIS
DOCUMENT
GENERAL SERVICE NOTES
EXPLANATION OF SIGNAL WORDS
Before you begin:
Read, understand and comply with:
• All instructions and procedures.
• All signal word (CAUTION, WARNING and
DANGER) statements to help avoid personal injury
or property damage.
• Company’s maintenance, service, installation and
diagnostic practices.
• Vehicle manufacturer’s safety instructions when
working on the vehicle.
• Vehicle manufacturer’s instructions for
recommended practices not described in this
manual.
• Local safety regulations.
IMPORTANT: Special attention should be paid to the
information included in EXPLANATION
OF SIGNAL WORDS.
This section explains the techniques used in this
document to convey important information, safety
issues and how to contact Hendrickson.
Hazard signal words (such as DANGER, WARNING
or CAUTION) appear in various locations throughout
this publication. Information accented by one of these
signal words must be observed at all times. Additional
notes are utilized to emphasize areas of procedural
importance and provide suggestions for ease of repair.
The following definitions comply with ANSI Z535.4
and indicate the use of safety signal words as they
appear throughout the publication.
DANGER:INDICATES IMMEDIATE HAZARDS
WHICH WILL RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
WARNING: Indicates hazards or unsafe practices
which could result in severe personal
injury or death.
DURING SERVICE:
• Work must be carried out by trained personnel.
• Sudden release of parking springs (e.g. the spring
brake part of the brake chamber or the brake return
spring) may cause injury.
• Use recommended tools only.
• Before releasing trailer back into service, perform
operational checks and test the trailer to ensure
brakes are working correctly.
CAUTION: Indicates a hazardous situation
which, if not avoided, could result in
minor or moderate injury.
NOTICE:Indicates hazards or unsafe practices
which could result in damage to
machine or equipment.
IMPORTANT: An operating procedure, practice
or condition that is essential to
emphasize.
Hendrickson reserves the right to make changes and
improvements to its products and publications at any
time. Consult the Hendrickson website
(www.Hendrickson-intl.com) for the latest version of
this manual.
Safety alert symbol used to indicate
a condition exists that may result in
personal injury or harm to individuals.
It must be applied to DANGER,
WARNING and CAUTION statements,
which emphasize severity.
IMPORTANT SAFETY NOTICES
Proper installation, maintenance, service and
repair is important to the reliable operation of the
suspension system. The procedures recommended
by Hendrickson and described in this publication
are methods of performing inspection, maintenance,
service and repair.
LINKS
Links are identified by a dark grey line under the
linked text. Internal links allow the reader to jump to a
heading, step or page in this document. External links
open the website or document referenced.
L64 G
The warnings and cautions should be read carefully
to help prevent personal injury and to assure that
proper methods are used. Improper maintenance,
service or repair can cause damage to the vehicle and
other property, personal injury, an unsafe operating
3
Welding Procedures 
condition and potentially void the manufacturer’s
warranty.
• Compressed air or dry brushing
should never be used for cleaning
brake assemblies or work areas.
Carefully read, understand and follow all safety related
information within this publication.
• Follow applicable shop, local,
state and federal safe practices for
working with and disposal of brake
lining materials.
WARNING:DO NOT modify or rework parts.
Use ONLY Hendrickson-authorized
replacement parts. Use of modified
or non-genuine replacement parts not
authorized by Hendrickson may not
meet Hendrickson’s specifications. It
can also result in failure of the part,
loss of vehicle control and possible
personal injury or property damage.
Do not modify parts without written
authorization from Hendrickson.
• Hendrickson recommends that
workers doing brake work should
take steps to minimize exposure
to airborne brake lining particles.
Proper procedures to reduce
exposure include:
–– Working in a well-ventilated
area,
–– Segregation of areas where
brake work is done,
–– Use of local filtered ventilation
systems or use of enclosed
cells with filtered vacuums.
WARNING:Always wear proper eye protection
and other required personal
protective equipment (PPE) when
performing vehicle maintenance,
repair or service. Follow federal,
state and local safety regulations as
appropriate.
• Material Safety Data Sheets
(MSDS) on this product, as
required by OSHA, are available
online from Hendrickson at
www.Hendrickson-intl.com/
trailerlit.
WARNING:Solvent cleaners can be flammable,
poisonous and cause burns. To
help avoid serious personal injury,
carefully follow the manufacturer’s
product literature and the following
procedures:
CAUTION:A mechanic using a service procedure
or tool has not been recommended
by Hendrickson 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 provided instructions
assume all risks of consequential
personal injury or damage to
equipment.
• Wear proper eye protection.
• Wear clothing that protects your
skin.
• Work in a well-ventilated area.
• DO NOT use gasoline or solvents
that contain gasoline. Gasoline
can explode.
NOTICE:When welding to or on the axle, take
every caution to prevent bearing
damage. When grounding welding
equipment to axle, prevent current
from passing through the wheel
bearings.
• Hot solution tanks or alkaline
solutions must be used correctly.
Follow the manufacturer’s
recommended instructions and
guidelines carefully to help
prevent personal accident or
injury.
A connection that places a wheel
bearing between the ground cable
connection and the weld area can
damage the bearing by electric
arcing.
WARNING:The following precautions and
considerations should be applied
when handling brake lining:
4
L64 G
Welding Procedures
CONTACTING HENDRICKSON
• Other selections include:
–– Aftermarket Sales for replacement parts
information and ordering.
–– Original Equipment Sales for parts inquiries
and ordering for trailer manufacturers.
Contact Hendrickson Trailer Technical Services for
technical assistance as needed. To do so, several
options are available. Technical Services must be
contacted before performing any warranty related
service.
EMAIL
To contact Hendrickson Trailer Technical Services, use
the following e-mail address:
Prior to contacting Technical Services, it is best to
have the following information about the vehicle and
Hendrickson suspension available (all that apply):
• Suspension ID Tag information (Refer to
Hendrickson Literature Number L977 Trailer
Suspension and Axle ID Guide, page 2 for tag
location and details):
–– Suspension model number
–– Suspension serial number
–– Approximate number of suspension miles
• VIN plate data. Refer to trailer OEM manual for VIN
plate location.
–– Trailer Type (van, reefer, flat bed, etc.)
–– Manufacturer
–– VIN (vehicle identification number)
–– In-service date 1
• If applicable, description of the system problem,
part number and/or part description of the reported
non-functioning part.
–– Date of problem
–– Where applicable: location of problem on
suspension / trailer (e.g., road side, front axle,
rear axle, curb side rear, etc.)
–– Symptoms»» Systems, components or function affected by
the problem.
»» When does the problem occur?
»» How often does the problem occur?
»» Etc.
• Any troubleshooting and/or measurements have
been performed.
• Digital photos of suspension and damaged areas.
• Special application approval documentation
(if applicable).
[email protected]
LITERATURE
If you suspect your version of this or any other
Hendrickson manual is not “Up-to-Date”, the most
current version is free online at:
www.Hendrickson-intl.com/TrailerLit
Available Hendrickson documentation can be viewed
or downloaded from this site.
All Hendrickson online documentation are PDF files
that require Adobe Acrobat Reader to open. This is a
free application downloadable from Adobe’s home
page (http://get.adobe.com/reader/).
Other relative literature may include:
NAME
If the in-service date is unknown or not available, the vehicle date of
manufacture can be substituted.
L64 G
B92
QUIK-ALIGN Pivot-Connection Fastener Upgrade
L341
INTRAAX® Installation Procedures
L427
Bushing Replacement Procedures
L459
Checking Trailer Ride Height
L577
HT™ Series Suspension Installation Procedures
L579
Alignment Procedures
L583
Comprehensive Warranty Statement
L1073
Primary Suspension Information (includes list of
installation drawings)
L1074
Slider Suspension Information (includes list of
installation drawings)
T19003
CAUTION - Welding to Galvanized Steel
Table 1: Literature
PHONE
Contact Hendrickson directly in the United States at
866‑RIDEAIR (743‑3247). From the menu, select:
• Technical Services/Warranty for technical
information.
1
DESCRIPTION
®
5
Welding Procedures 
RECOMMENDED WELDING PRACTICES
SMAW
Unless otherwise specified, these welding practices
must be applied when welding to Hendrickson Trailer
suspension systems.
AWS E-7018 (Oven Dried)
• 0.125 diameter
120-140 Amps D.C.
DCRP
• 0.156 diameter
120-160 Amps D.C.
DCRP
WARNING: Failure to follow these procedures
and specifications can cause damage
to the axle or suspension, and result
in serious injury, death or property
damage.
GMAW - Spray Transfer
WELDING PARAMETERS
NOTE:Welds must be performed by a welder
qualified in 2G position per www.aws.org
“Performance Qualification”.
• Suspension components and their mating parts
must be at a minimum temperature of 60ºF
(15.5ºC) and must be free from moisture, dirt,
scale, paint and grease.
• It is recommended that all axle to suspension
trailing arm welds be hammer peened. See AXLE
WELD HAMMER PEENING on page 12.
• All welds must be performed in a flat or horizontal
position.
• Unless otherwise specified, welds must terminate
0.5 inch (12.7 mm) from edge of parent metal.
NOTICE:Welding to the edge of parent
material risks inducing cracking of
the metal.
• Achieve spray arc transfer with the following
welding parameters:
Standard Wire:
AWS ER-70S-6
• 0.045 diameter
(i.e., L-56 or NS-115)
Optional Wire:
AWS ER-70S-3
• 0.045 diameter
(i.e., L-50 or NS-101)
Voltage:
26-30 Volts DCRP
Current:
275-325 Amps
Wire Feed Speed:
380-420 IPM
Electrode
Extension:
3
Gas:
85% Argon 15% CO2
at 30 to 35 CFH
/4 inch - 1 inch
NOTE:Any deviation from these welding parameters
must be approved in writing by Hendrickson
Trailer Suspension Systems.
WELDING AREA PREPARATIONS
Prior to welding, the following preparation is
recommended:
1. Remove all surface coat, dirt and rust in touch-up/
repair location.
2. Thoroughly clean the area. Using a clean cloth,
wipe the surface to remove any residue from
previous step.
The repair surface area shall be clean, dry and
free of all contamination, e.g. oil, grease, preexisting coating.
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L64 G
Welding Procedures
WELDING SYMBOLS
Shown below in Figure 1, are the welding symbols
typically found on Hendrickson suspension products.
Length of Weld
{
Tail (Omitted when
reference is not used)
Weld Symbol
Other
Side
S(E)
{
Arrow
Side
T
{
Sides
Specification,
process or
other reference
Pitch (Center-To-Center
Spacing) of Welds
Metric equivalent of S
Both
Depth of Bevel; Size or
Strength for Certain Welds
{
Weld-all around
L-P
Elements in this area
remain as shown when
tail and arrow are reversed
Fillet Weld
Plug Weld
Arrow
Side
Flare-V Weld
S
Diameter of plug weld
Other
Side
S
Both
Sides
Figure 1: Weld Symbols
L64 G
7
Flare-Bevel Weld
Welding Procedures 
SUSPENSION BEAM TO AXLE WELD
PARAMETERS
(HT™ SERIES SUSPENSIONS ONLY)
IMPORTANT: At least one side of each axle seat
radius must be tight against the axle.
Any resulting gap must be no more
than 1/16 inch (1.6 mm), Figure 2.
All axle welds must be performed while in a horizontal
or flat position.
Front axle seat
NOTE:The following welding procedures are for
horizontal (2F) positioning only.
Beam centers
1.0” (25.4 mm) tack
Weld - (2) req’d
Front only
IMPORTANT: Preheating the axle connection at the
axle and suspension seat may be
recommended and/or required by the
axle manufacturer. Consult the axle
manufacturer for their axle preheating
specifications and the applicable effect
on their warranty coverage.
Front
SUSPENSION BEAM AND AXLE SETUP
Figure 3: Locations of tack weld
1. Refer to L577 HT™ Series Suspension Installation
Procedures to properly locate and position the
axle in the suspension beam axle seats.
3. Place a 1 inch (25.4 mm) long tack weld
(Figure 3) on the front axle seat in the center of
each suspension beam/axle connection, one tack
weld is required per suspension beam.
NOTE:If a Hendrickson HT axle locating fixture
is used, setup details can be found in
Hendrickson literature number L577 HT Series
Suspension Installation Procedures available
at www.Hendrickson-intl.com/TrailerLit.
Refer to the section titled “USING HT SERIES
FIXTURES”
SUSPENSION TO AXLE WELD PROCEDURE
Complete the weld following the information
provided in the following headings:
A. WELD PASS LENGTH AND POSITION on
page 9
If not using an axle locating fixture, refer to the
section titled “AXLE INSTALLATION WITHOUT
AN AXLE LOCATING FIXTURE”.
B. WELD PASS SIZE AND PLACEMENT on
page 10
C. WELD DIRECTION AND SEQUENCING on
page 11
2. Use a clamping device to secure the centered axle
onto the positioned beams as instructed in L577.
D. AXLE WELD HAMMER PEENING on
page 12
IMPORTANT: Read and understand this information
prior to applying the welds. The
following methods for welding the
suspension beams to the axle must
be applied to continue warranty for the
suspension and/or axle.
Gap to be no
More than 0.06"
(1.6 mm)
Figure 2: Axle seat gap
8
L64 G
Welding Procedures
WELD PASS LENGTH AND POSITION
Figure 4 shows the length and position of the axle
weld. All weld passes are to be performed as shown.
IMPORTANT: The weld length is dependent on the
type of suspension being installed.
When installing the HT190T, HT190U,
HT230T, HT250T, HT250US, HT250YS,
HT300T and HT300US use left figure.
When installing the HT250U and
HT300YB, use right figure.
0.625+0.0/-0.25"
(15.9 +0.0/-6.4 mm)
Suspension
Beam
1.125 +0/-0.25"
(28.6 +0.0/-6.4 mm)
7.00 ±0.25"
(177.8 ±6.4 mm)
Axle Weld Length
Front
See Figure 9
and Figure 10
Axle
Front
Important
DO NOT wrap
welds around
axle seat corners
Axle
See Figure 9
and Figure 10
Denotes weld placement
Axle
seat
Denotes weld placement
HT250U and HT300YB
HT190T, HT190U, HT230T, HT250T, HT250US, HT250YS,
HT300T and HT300US
Figure 4: Axle weld pass length and position.
L64 G
6.50 ±0.25"
(165 ±6.4 mm)
Axle weld length
9
Welding Procedures 
WELD PASS SIZE AND PLACEMENT
NOTE:All axle seat connections require three weld
passes to be performed as shown. Figure 5
shows the location and size of each weld.
Front axle seat
Rear axle seat
See enlarged
views below
2F
Front Axle Seat
0.31"
(7.9 mm)
leg on axle
Rear Axle Seat
0.25" (6.4
mm) min
0.25" (6.4
mm) min
0.25" x 0.31"
(6.4 x 7.9 mm)
0.25" x 0.31"
(6.4 x 7.9 mm)
Root
weld
0.31" (7.9 mm) min
0.38"
(12.7 mm)
leg on axle
0.38" x 0.5"
(9.7 x 12.7 mm)
0.31" (7.9 mm) min
0.5" (12.7
mm)
0.38" (9.7
mm)
0.38" x 0.5"
(9.7 x 12.7 mm)
Second
pass
0.38" (9.7 mm)
0.44"
(11.2 mm)
leg on axle
0.38" x 0.44"
(9.7 x 11.2 mm)
0.31"
(7.9 mm)
leg on axle
0.38"
(12.7 mm)
leg on axle
0.38" (9.7 mm)
0.38" (9.7
mm)
0.38" (9.7
mm)
Third
pass
0.44" (11.2 mm)
0.38" x 0.44"
(9.7 x 11.2 mm)
0.44"
(11.2 mm)
leg on axle
0.44" (11.2 mm)
Figure 5: Axle weld passes — all HT™ Series suspensions
10
L64 G
Welding Procedures
WELD DIRECTION AND SEQUENCING
Figure 6 explains weld symbols used in this procedure
for direction and sequence.
Sequence
number
Weld
beginning
1
Weld
direction
Figure 6: Weld Instructions legend
NOTE:The following instructions for direction and
sequence must be followed when applying the
weld.
2. Continue with the second and third weld passes
after all four root passes, Figure 8.
CAUTION:Avoid all cold laps and undercuts. Fill
all craters. Clean the weld between
each pass. If these steps are not
followed, failure may occur with the
axle-to-suspension connection.
Figure 7: Root pass sequence
1. Beginning on the rear side of the axle/seat
connection, place four single root pass welds,
Figure 7.
L64 G
Figure 8: Second and third pass weld sequences
11
Welding Procedures 
AXLE WELD HAMMER PEENING
It is recommended that peening shall be done using
a pneumatic hammer. The radius of the peening tool
shall be approximately 0.188” (4.78 mm).
Hammer peening after welding relives the thermal
stresses as a result of welding.
NOTICE: Use of needle scaler or needle
hammer for peening shall not be
acceptable.
Allow final weld to cool down to less than 400°F
(204°C) before continuing.
Visually inspect the final for defects prior to peening.
After peening, there shall be no divots or craters and
the surface shall be dimpled, resembling that of an
orange peel, Figure 9.
Peening process shall target a peening depth of 0.03”
(0.76 mm). The target diameter of peening dimples
shall be 0.10” (2.54 mm).
Beam to Axle Weld, peen the toe of the weld only.
0.500 +0.250/-0.1"
(12.7 +6.4/-2.5 mm)
See
Detail A
Hammer peen
1.000 +0.250/-0.0"
(25.4 +6.4/-0.0 mm)
0.500
+0.250/-0.1"
(12.7 +6.4/2.5 mm)
Weld
End of weld
0.625 +0.500/-0.0"
(15.9 +12.7/-0.0 mm)
Detail A
Figure 9: Beam to axle weld peening details
12
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Welding Procedures
WIDE FRAME BRACKET WELDING
PROCEDURES
Vertical supports should be
over front face and rear
face of frame bracket.
NOTE: For narrow frame bracket details, refer to
instructions listed in applicable suspension
installation drawings 2.
A
A
A
A
A
10.5"
(267 mm)
Reference
A
Figure 11: Typical wingless frame bracket attachment
WELD-ON FRAME BRACKETS
Wide Wingless
Figure 10: Typical weld-on frame brackets
NOTE:Unless otherwise noted, all welds are to be ¼
inch (6.4 mm) minimum. For more details,
refer to applicable suspension installation
drawings and literature.
IMPORTANT: Starting and stopping points should
be no closer than ½ inch (12.7 mm)
from the mating edge of the suspension
component and the trailer frame and/or
the cross members.
NOTE:It is the responsibility of the suspension
installer and the vehicle designer to provide
both adequate vehicle frame design and the
proper securing method for the suspension
system.
An installation drawing is provided with each suspension type.
Generic versions are listed in Hendrickson literature number L1073
and available online at www.Hendrickson-intl.com/TrailerLit. Where
duplication exists, refer to the installation drawing.
L64 G
A
A
The following figures are examples of typical
suspension installations. Reference specific
suspension drawings for actual installation details.
The procedures illustrated may need to be adapted
due to varying trailer designs.
2
A
A = 0.5" (12.7 mm)
No weld
Figure 10 through Figure 15 illustrate frame bracket
welding procedures. Weld the frame brackets to
the trailer frame using the parameters given in
RECOMMENDED WELDING PRACTICES on page 6.
Wide Winged
A
13
Welding Procedures 
Vertical supports should
be over front face and
rear face of frame bracket
A
A
A
A = 0.5" (12.7 mm) No weld
A
A
A
A
A
A
See View "A" 0.60" (0.43")
A
A
10.5"
(267 mm)
Reference
A
A
A
A
[15.2 mm (10.9 mm)]
0.38" (9.7 mm)
View "A"
Weld Cross Section
Cross member
0.60" (15.2 mm)
0.43" (10.9 mm)
0.38" (9.7 mm)
0.38" (9.7 mm)
NOTE:The suspension installer
has the responsibility to
determine the proper welding
parameters for the materials
being used. For specifications
of the suspension component
material, refer to CONTACTING
HENDRICKSON on page 5.
Figure 12: Typical winged frame bracket attachment
Winged frame bracket
Trailer front
Crossmember
Crossmember
NOTE:A crossmember must provide support for wings
Top View
Figure 13: Frame bracket installation for QUIK-ALIGN® models with winged frame brackets.
14
L64 G
Welding Procedures
Additional support needs to be provided by the OEM
when frame brackets extend beyond the trailer frame
rail more than 1/2 inch (12.7 mm).
If the frame bracket location
is such that the outer face
of frame bracket is not
adequately supported,
additional OEM supplied
gussets may be required as
shown here. Other methods of
support may be preferred.
Outer edge must
be supported
Figure 14: Extreme offset frame bracket attachment; winged or
wingless
Vertical supports should be over front
face and rear face of frame bracket.
Approximate bolt locations
Gussets must be used to distribute loads
from front corners of frame bracket into
bolts (not supplied by Hendrickson).
2.0" (50.8 mm)
0.2" (5.1 mm)
No weld
Gap to be no more than
0.12” (3.0 mm). Use
restraints if necessary
10.5"
(267 mm)
Reference
0.5" (12.7 mm) No weld
Figure 15: Frame bracket-to-mounting plate attachment (customer supplies bolt-on plate and gussets)
For position and other details, refer to applicable suspension installation drawings 3
3
An installation drawing is provided with each suspension type. Generic versions are listed in Hendrickson literature number L1073 and available
online at www.Hendrickson-intl.com/TrailerLit. Where duplication exists, refer to the installation drawing.
L64 G
15
Welding Procedures 
C-CHANNEL WELDING PROCEDURES
Hendrickson has a variety of frame bracket support options and recommendations. Hendrickson Engineering
should be contacted to review any application. When a C-channel is required, attach it to the frame brackets as
shown in Figure 16. Refer to RECOMMENDED WELDING PRACTICES on page 6 for weld parameters.
Applies to all frame brackets
3.63 ±0.10"
(922 ±2.5 mm)
0.5" (12.7 mm)
0.25" (6.4 mm)
0.25" (6.4 mm)
0.25" (6.4 mm)
0.5" (12.7 mm)
0.25" (6.4 mm)
1.0" (25.4 mm)
1.0" (25.4 mm)
For 41 inch (1041 mm) beam centers
For 35 inch (889 mm) beam centers
Denotes weld placement
(All dimensions in inches unless noted otherwise)
Figure 16: Typical C-channel attachment
For position and other details, refer to applicable suspension installation drawings 4.
4
An installation drawing is provided with each suspension type. Generic versions are listed in Hendrickson literature number L1073 and available
online at www.Hendrickson-intl.com/TrailerLit. Where duplication exists, refer to the installation drawing.
16
L64 G
Welding Procedures
FRAME BRACKET GUSSET WELDING PROCEDURE
When frame bracket gussets are required, attach them as shown in Figure 17. Refer to RECOMMENDED
WELDING PRACTICES on page 6 for weld parameters.
0.25" (6.4 mm)
0.25" (6.4 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.50" (12.7 mm)
0.25"
(6.4 mm)
0.25"
(6.4 mm)
See
View “A”
See View “A”
0.50" (12.7 mm)
0.50"(12.7 mm)
1.25"
(31.7 mm)
Denotes weld placement
(All dimensions in inches unless noted otherwise)
View “A”
1.50"
(38.1 mm)
Cross member
0.60" (15.2 mm)
0.43" (10.9 mm)
0.15" (3.8 mm)
0.38" (9.6 mm)
1.25" (31.7 mm)
Figure 17: Frame bracket gusset attachment
For position and other details, refer to applicable suspension installation drawings 5.
5
An installation drawing is provided with each suspension type. Generic versions are listed in Hendrickson literature number L1073 and available
online at www.Hendrickson-intl.com/TrailerLit. Where duplication exists, refer to the installation drawing.
L64 G
17
Welding Procedures 
INTRAAX® SUSPENSION AIR
SPRING MOUNTING PLATE WELDING
PROCEDURES
1. Position air spring mounting plates per
specifications listed in installation drawings 6.
2. Tack weld mounting plates into place, Figure 18
or Figure 19.
Weld these components to the trailer frame using
the parameters given in WELDING PARAMETERS on
page 6.
0.19"
(4.8 mm)
3. Recheck position and adjust as needed.
IMPORTANT: Refer to RECOMMENDED WELDING
PRACTICES on page 6 for weld
parameters.
TYP
4. Weld mounting plate with spacer to trailer frame
(Figure 18 A) or crossmember (Figure 18 B). Refer
to installation drawings for more details.
NOTICE:DO NOT ATTACH air spring mounting
plate or air spring to BOTH the trailer
main rail and trailer crossmember.
Air spring mounting is not designed
to resist movement between the
trailer crossmember and frame rail.
0.19"
(4.8 mm)
TYP
A. Weld to trailer frame rail
0.19"
(4.8 mm)
TYP
B. Weld to crossmember
Figure 18: Air spring weld-on mounting plate
A. Weld to trailer
frame rail
B. Weld to
crossmember
6
Figure 19: Air spring weld-on mounting plate, ISO view.
18
An installation drawing is provided with each suspension type.
Generic versions are listed in Hendrickson literature number L1073
and available online at www.Hendrickson-intl.com/TrailerLit. Where
duplication exists, refer to the installation drawing.
L64 G
Welding Procedures
HT™ SERIES SUSPENSION AIR
SPRING MOUNTING PLATE WELD
NOTICE:DO NOT ATTACH air spring mounting
plate or air spring to BOTH the trailer
main rail and trailer crossmember.
Air spring mounting is not designed
to resist movement between the
trailer crossmember and frame rail.
The HT Series suspension air springs are attached
similar to the INTRAAX air springs. However, when rear
shocks are used on HT Series suspensions the shock
clevis may be attached to the upper mounting plate.
Weld these components to the trailer frame as shown
in Figure 20 to Figure 25 and WELDING PARAMETERS
on page 6.
2X weld
2.00±0.25"
(50.8±6.4 mm)
Trailer frame rail
Roughly 60% of upper air spring
plate should be supported. If
the air spring mounting plate is
inboard of the frame rail, additional
support gussets may be required.
NOTE:Support for shock
bracket may be required.
See suspension
installation drawing for
load input information.
Forward
Trailer crossmember
Figure 20: Typical air spring mounting plate attachment
2X weld
2.00±0.25"
±
(50.8 6.4 mm)
Trailer frame rail
Roughly 60% of upper air spring
plate should be supported. If the air
spring mounting plate is inboard
of the frame rail, additional support
gussets may be required.
Possible gusset location.
Other methods of support
may be preferable.
Forward
NOTE:Support for shock bracket may be required. See
suspension installation drawing for load input information.
Trailer crossmember
Figure 21: Severe offset attachment
For positioning and other details on mounting air spring plate, refer to installation drawings 7. For HT Series
suspensions, refer to Hendrickson literature number L577 HT Series Suspension Installation Procedures at
www.Hendrickson-intl.com/TrailerLit.
7
An installation drawing is provided with each suspension type. Generic versions are listed in Hendrickson literature number L1073 and available
online at www.Hendrickson-intl.com/TrailerLit. Where duplication exists, refer to the installation drawing.
L64 G
19
Welding Procedures 
Trailer frame rail
NOTE:Rear portion of
spacer should
be adequately
supported.
If the rear portion of the spacer is
inboard of the frame rail, additional
support gussets may be required.
Forward
NOTE:Support for shock bracket
may be required. See
suspension drawing for
load input information.
Trailer crossmember
Figure 22: Typical air spring mounting plate with spacer attachment
Trailer frame rail
If the rear portion of the spacer is
inboard of the frame rail, additional
support gussets may be required.
Possible gusset location.
Other methods of support
may be preferable.
Forward
NOTE:Support for shock bracket
may be required. See
suspension drawing for
load input information.
Trailer crossmember
Figure 23: Severe offset with spacer attachment
0.5" (12.7 mm)
No weld
0.25"
(6.4 mm)
0.5" (12.7 mm)
No weld
Weld length
will vary
depending on
ride height.
0.25"
(6.4 mm)
Figure 24: Shock clevis attachment without spacer
Weld length
will vary
depending on
ride height.
Figure 25: Shock clevis attachment with spacer
20
L64 G
Welding Procedures
HT™ SERIES Y-BEAM SUSPENSION BUSHING TUBE WELDING
For reference
90 Degrees
Trailer frame rail
Bushing tube sleeve
0.25" (6.4 mm)
X2
Each frame
90 Degrees
XXXXX XXXXXX
XXX
XX
XX
XX
XX
XXXXXXXXXXX
XXX
XX
XX
XX
XX
XXXXXXXXXXX
XXX
XX
XX
XX
XX
XXXXXXXXXXX
XXX
XX
XX
XX
XX
Figure 26: Bushing tube sleeve installation
For more details on the HT Series Y-beam suspension
installation instructions refer to applicable installation
drawings 8 and Hendrickson literature number L577
HT Series Suspension Installation Procedures at
www.Hendrickson-intl.com/TrailerLit.
Trailer frame rail
Bushing tube sleeve
WELDING BUSHING TUBE SLEEVES
Customer-supplied bushing
tube sleeve support braces
(gussets)
1. Weld the complete circumference of both sides of
each bushing tube and sleeve to the web of the
trailer frame.
Figure 27: Bushing tube sleeve support brace installation
NOTICE:The bushing tube sleeve must not
contain a TRI‑FUNCTIONAL® Bushing
at this time.
2. Install additional support braces (gussets) to the
bushing tube sleeves, Figure 27. These braces are
customer supplied and should resist all fore, aft
and vertical loading of the bushing tube sleeve.
8
An installation drawing is provided with each suspension type.
Generic versions are listed in Hendrickson literature number L1073
and available online at www.Hendrickson-intl.com/TrailerLit. Where
duplication exists, refer to the installation drawing.
L64 G
21
Welding Procedures 
REBOUND LIMITER OPTION
WELDING BUSHING TUBE ASSEMBLIES
Rebound limiters (down stops) are optional for
some suspension models. A chain is typically used
(Figure 30) for AAL, AAEDL and AAEDT suspension
types with wide frame brackets. Down stops are
attached between the trailer frame and the suspension
beam as shown. Refer to the applicable suspension
installation drawing 9 or kit installation drawing for
positioning and weld specifications.
CAUTION: Allow adequate cooling between
welds to prevent excessive heating of
the TRI-FUNCTIONAL® Bushing.
Weld bushing tube assemblies (Figure 28) to their
respective bushing tube sleeves by using four 1/2 inch
(12.7 mm) long welds equally spaced around the
perimeter on both sides. Refer to L427 Bushing
Replacement Procedures for the pivot connection
assembly procedures.
Void orientation
(vertical)
0.25"
(6.4
mm)
.50"
(12.7 mm)
XXXXXX
XXXXXX
Bushing tube sleeve
XXXX XX
Both
sides,
4 welds
evenly
spaced
Trailer
frame rail
Non-void
orientation
(horizontal)
XXXXXX
Bushing tube assembly
Figure 30: AAEDT with chain down stop
Figure 28: Bushing tube assembly position
ATTACHING REAR SHOCK CLEVIS
WELDED COLLAR PIVOT CONNECTION
When rear shocks (Figure 31) are used on INTRAAX
or HT™ Series suspensions, the upper shock clevis
may be welded to the trailer frame or crossmember,
but not both; similar to Figure 24 and Figure 25
on page 20. Refer to the applicable installation
drawing for positioning and weld specifications.
This pivot connection requires collars to be welded
to the frame bracket as shown in Figure 29. Refer to
L579 Alignment Procedures for alignment procedure
details.
Rear shock
Front shock
XX
XXXXX XXXXXXX
XXX
XX
XX
XX
XX
XX
XX
XXXXXXXXXXXXX
XXX
XX
XX
XX
XX
XX
XX
XXXXXXXXXXXXXX
XXX
XX
XX
XX
XX
XX
XX
XXXXXXXXXXXXXX
XX
XXX
XX
XX
XX
XX
XX
Figure 29: HT230T suspension with welded collar
Figure 31: AAEDT with front and rear shocks
9
22
An installation drawing is provided with each suspension type. Generic
versions are listed in Hendrickson literature number L1073 and
available online at www.Hendrickson-intl.com/TrailerLit.
L64 G
Welding Procedures
HT™ SERIES REMOTE SHOCK CLEVIS
XXXXXXXXXXXXXXXXXXXXXXXXXX
For some HT™ Series suspension models, the lower shock clevis is welded to the axle as shown in Figure 32.
In this case the remote upper shock clevis is welded to a frame crossmember. For positioning and weld
specifications, refer to the installation drawing and Hendrickson literature number L577 HT Series Suspension
Installation Procedures at www.Hendrickson-intl.com/TrailerLit. If weld specifications are not included in the
installation drawing, refer to Figure 32 or CONTACTING HENDRICKSON on page 5.
No weld permitted
on axle radius
0.25
0.25
4X
Denotes
weld
placement
Figure 32: Remote shock mount weld specifications
WELDING TANK BRACKETS TO SLIDER BOX
All tank brackets welded to the slider box structure must be done so using a window weld as shown in
Figure 33. This applies to either the installation of a tank bracket to the slider or the repair of the tank
bracket weld to the slider. Butt or plug welding is not allowed and may cause cracks in slider box structural
components.
Any welds on the slider must first be approved by Hendrickson.
DO NOT WELD
XXX
XXXXX
XXX
DO NOT WELD
XX
XX
XX
X X X XXXXXXXXXXX XXXXXXXXXXXX X X X X X
XXXXXXXXXXXXXXXXXXXXXXXXX X X X
XX
XX
XX
XX
0.19
(4.8 mm)
XXX XXXX
X
DO NOT WELD
Figure 33: Tank bracket window weld
L64 G
23
2X - [TANDEM]
4X - [TRIAXLE and 120" Spread]
WELDING TO GALVANIZED STEEL
Some or all steel components on a suspension may
be galvanized. Occasionally authorized additions
or repairs may require welding to galvanized coated
steel. When this occurs, additional cautions and
considerations are applicable, different from welding to
plain steel.
WARNING:According to OSHA - “Zinc is used in
large quantities in the manufacture
of brass, galvanized metals and
various other alloys. Inhalation of
zinc oxide fumes can occur when
welding or cutting on zinc-coated
metals. Exposure to these fumes is
known to cause metal fume fever.
Symptoms of metal fume fever are
very similar to those of common
influenza. They include fever (rarely
exceeding 102° F), chills, nausea,
dryness of the throat, cough, fatigue
and general weakness and aching of
the head and body. The victim may
sweat profusely for a few hours, after
which the body temperature begins
to return to normal. The symptoms of
metal fume fever have rarely, if ever,
lasted beyond 24 hours.”
CAUTION:Appropriate PPE (Personal Protective
Equipment) should be used while
working with galvanize coatings, e.g.
eye, face, hand, foot and respirator
protection. Repairs on galvanized
coatings should be conducted in
accordance with ASTM A780M
Standard Practice for Repair of
Damaged and Uncoated Areas of HotDip Galvanized Coatings.
1. Remove all galvanized coating in touch-up/repair
location.
2. Thoroughly clean the area:
A. Using a clean cloth, wipe the surface to
remove any residue from previous step.
B. The repair surface area shall be clean, dry
and free of all contamination, e.g. oil, grease,
pre-existing coating.
3. Weld required components according to
ASTM A780M.
4. Paint cleaned and/or repaired areas using zinc
rich primer that meets the requirements of
ASTM A780 (97% zinc in dry film).
A. Before brushing or spray application, make
sure paint is thoroughly stirred or shaken.
B. Allow paint to cure as per paint supplier’s
recommended practice.
5. Measure dry film thickness.
NOTE:The thickness of coating should be at least
equal to the galvanized layer. Zinc rich primer
will give a dull, flat appearance, different
than a bright and shiny galvanized layer. The
performance of the paint is comparable to
galvanized steel.
6. The primer needs to be top coated with
a galvanizing paint meeting ASTM A780
specifications. This will provide protection and
give similar appearance to galvanized steel.
CAUTION:All safety precautions should be taken
during all cleaning and repair stages.
Call Hendrickson at 866.RIDEAIR (743.3247) for additional information.
TRAILER COMMERCIAL VEHICLE SYSTEMS
2070 Industrial Place SE
Canton, OH 44707-2641 USA
866.RIDEAIR (743.3247)
330.489.0045 • Fax 800.696.4416
www.hendrickson-intl.com
L64 Rev G 02-16 ECN 25055
Rev F 11-14 ECN 21798
Rev E 01-00
Rev D 05-97
Hendrickson Canada
250 Chrysler Drive, Unit #3
Brampton, ON Canada L6S 6B6
800.668.5360
905.789.1030 • Fax 905.789.1033
Hendrickson Mexicana
Circuito El Marqués Sur #29
Parque Industrial El Marqués
Pob. El Colorado, Municipio El Marqués,
Querétaro, México C.P. 76246
+52 (442) 296.3600 • Fax +52 (442) 296.3601
Rev C 02-96
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.
© 2016 Hendrickson USA, L.L.C. All Rights Reserved
Printed in United States of America
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