TRAILER AXLES INSTALLATION AND OPERATION MANUAL TRAILER AXLES Delivering Suspension Solutions Delivering Suspension Solutions For more information, call 800.445.0736 11621.SLDDRW 4/28/2009 8:36 AM WELD PROCEDURE FOR MONO PIVOT BUSHING TYPE ARMS Welding Procedures Preparation Warning ! Clean welds between passes and incorporate tacks REFER TO ES006 FOR ALIGNMENT TO AXLE into the first pass on the tacked side. Fill weld craters and 1. The surface must be free of paint, water, avoid undercuts and cold laps over welds. and other contaminants where welding is to occur. Welds should not be started or stopped at the end of the weld pass. 2. Suspension parts must be at least 60°F. * Normal They should stopped and started away from the ends as shown in Figure 7. recommendations is to preheat Do not wrap the corners of the axle seat while welding. 100-300 degrees F. 1. Three passes are required on each area where the axle is welded to the arms. * Note: Some axle manufacturers recommend preheating Figure 6 shows the size of the weld of each pass. the axle before it is welded. Consult the axle 2. Start welding in the sequence shown in Figure 7 at the rear side where the axle manufacturer for recommended guidelines on and seat meet . Make all first pass welds at all areas before proceeding to the welding to the axle. second pass. 3. Welding needs to be done in a flat horizontal position. 3. Figure 7 also shows the length of weld for both overslung and underslung models. Welding Axle to Suspension WELD PROCEDURE FOR COMMON: Weld Specifications Caution ! The welding procedures must be followed carefully to avoid damage to the axle and suspension which could cause an accident and or serious personal injury. 44 TA250/300 TOP MOUNT TA250/300 UNDERSLUNG AL2300 DESCRIPTION: AXLE SEAT WELDING PROCEDURE SHEET: 2 OF 2 DATE: SCALE: DRAWN BY: SIZE: DRAWING NO: 04/22/09 1:8 tgreaves B 11621 Table ofContents WC Weld Procedure WC Weld Procedure WheelEndL For Recommendations Procedures Adjustment Bearing Wheel maintenance and Removal,Installation BrakeAdjuster Manual Self-Adjust and Specifications Torque Fastener 24 Axle Lubrication 16.5” X-Reference Brake PartNumber Model WCP 16.5” X-Reference Model WCNBrakePartNumber 12.25” X-Reference Model WCNBrakePartNumber Axle Options Spacing Air Chamber Certification Brake Lining Model WCP Model WCN Guide Numbering WC AxlePart Ax WC le A ppli cat ion G uide ub rication rication 1 REV 5/24/2011 Literature #W&C207 35 21 3 2 43 23 20 31 22 16 19 17 10 4 18 1- Followt Recommendations: W running a wall axleth 3- C rough 2- Mini a W W p a acit m t hen in hen theapplicationsinvolves s roads u y on &Chalin m c m wall h h s a a a t e - n wasidenti alling theaxleonairsuspensionsorhi r jority ofti t select W . thickness a tson &Chalin“Nor the m next f e to ied on onhighwaytravelwith“ Axle be heav WCN WCP Axle used W ier running asignificant a Application Guide tson &Chali on tube wallthanwasidentified Outer Outer m Inner Inner Outer CupH Outer CupH Inner cupHM518410 Inner cupHM218210 a an l Service”Capac cone cone air cone cone Bear ride HM518445 HM218248 ing HM518445 HM212049 M M n “ 518410 212010 suspension s gh torsionsinglepivotsuspensions-selectthetube AIR RIDESUS SPRING SUSPENSION 2 ity m ount chart Bea is 26000/11800 25000/11350 ofoff-road 0.58” r (lbs/Kg) ing to on theapplicableWatson&Chalin P select Capaci ENSION * an t m y ” iles, oronexceptionally axle installedonit. ” Capacity for applicatio chart. n s 11621.SLDDRW 4/28/2009 8:36 AM REV. DESCRIPTION ECN DATE BY NOTES: A NEW DRAWING - 03/01/95 RON WELD PROCEDURE 1. AXLE SEATS TO BE CLAMPED SECURELY IN THE PROPER POSITION WITH B CORRECTED NOTE 4 3042 12/03/03 JFF ARMS PARALLEL AND SQUARED IF ASSEMBLED. FOR 1/2 ROUND ARM/SEAT 2. THE WELDING RODS SHOULD CONFORM TO AWS GRADE E-7018 (OVEN-DRIED) C ADDED DANA & MERITOR SPECS 3042 12/09/03 JFF OR COMPARABLE. USE COMPARABLE WIRE IS USING MIG WELDER. D ADDED SUDISA NOTE 4 3042 12/10/03 JFF TO AXLE ONLY DO NOT 3. AXLE TUBE AND AXLE SEATS MUST BE CLEANED. E CHANGED NOTE 4 & 6 C-5073 12/26/07 EFR 3.00 WELD IN 4. DO NOT WELD AXLES WHEN AXLES ARE COLD. NORMAL PREHEAT FOR OTHERS SEE PAGE 2 THIS AREA! RECOMMENDATIONS ARE BETWEEN 100 AND 300 DEGREES F. CONSULT F CHANGED NOTE 4 BACK C-5305 04/03/08 EFR TOP AXLE MANUFACTURER IF NECESSARY. G INTO SOLIDWORKS AND UPDATED C-6299 4/22/2009 TEG E --IMT REQUIRES 60-200 F PRIOR TO WELDING. --DANA REQUIRES AXLE AND MATING BRACKETS MUST BE 60 F PRIOR TO WELDING. F --MERITOR REQUIRES AXLE TUBE AND HARDWARE BEING WELDED TO AXLE TO BE 2.00 MAX MINIMUM OF 60 F PRIOR TO WELDING. ACCEPTABLE D --SUDISA REQUIRES AXLE TUBE AND HARDWARE BEING WELDED TO AXLE TO BE WELD AREA MINIMUM OF 60 F PRIOR TO WELDING. 1.50 MAX IF OTHER MANUFACTURER'S AXLE IS USED, CONSULT THEM PRIOR TO WELDING, FOR PREHEAT SPECIFICATIONS. 5. APPLY WELDS IN THE SIZES AND SEQUENCE SHOWN IN FIRGURE 1, AND 3. APPLY WELDS IN AREAS SHOWN IN FIGURE 4. THE ELECTRODE SHOULD BE BACKED UP TO FILL IN THE FILLET CRATER AT THE END OF EACH PASS. BOTTOM E THE CORNERS SHOULD BE WRAPPED. CLEAN THE WELD BETWEEN EACH PASS. 4.00 DO NOT 6. SEQUENCE 1 SHOULD BE PERFORMED ON BOTH AXLE SEATS PRIOR TO WELD IN CONTINUING WITH PASSES 2 AND 3. THE SEQUENCE SHOULD BE PASS #1 FIGURE2 THIS AREA! ON BOTH AXLE SEATS, THEN PASS 2 AND 3 ON EACH SEAT IN SERIES. 3 PASS 3 PASS 2 PASS 2 PASS FIGURE 3 1 PAS1.0S 0 1 PASS C C L AXLE 1.00 L AXLE 43 SEE FIGURE 2 FOR MAX CL START FIGURE 1 START WELD PROCEDURE FOR 1/2 ROUND ARM/SEAT TO AXLE ONLY FOR OTHERS SEE PAGE 2 DO NOT "TEST THE ARC" ON THE AXLE BEAM WELD PROCEDURE FOR 1/2 ROUND ARM/SEAT .38 .50 TO AXLE ONLY .38 .38 .50 FOR OTHERS SEE PAGE 2 DEPTS TOLERANCES DESCRIPTION: AFFECTED (EXCEPT AS NOTED) AXLE SEAT WELDING SPECS DECIMAL PREVIOUS ASSY: SHEET: - .06 - 1 OF 2 FRACTIONAL SUSPENSION MODEL: SCALE: FIRST PASS SECOND PASS THIRD PASS - 1/16 - 1:1 WEIGHT: ANGULAR DATE: DRAWN BY: SIZE: DRAWING NO: FIGURE 3 NOTE: PARENTHESIS ( ) DENOTES REFERENCE DIMENSION - 1 03/01/95 RON B 11621 42 Watson & Chalin Axle Part Numbering Guide Prefix Spindle type Wall Thickness Brake Size Axle type Track Width Numbering WC N 5 67 ST 715 -XXX N Spindle or N* D22 3 10mm 27 12.25 x 7.5 ST Straight 715 71.5” P Propar type 4 0.5 67 16.5 x 7 6D 6” Drop 730 73.0” F FF Spindle 5 0.58 54 15 x 4 9D 9” Drop 775 77.5” A26/K30 K Spindle 6 0.75 87 18 x 7 6I 6” Inverted Drop 955 95.5” A A45 Spindle S Solid 9I 9” Inverted Drop 120 120” By 1/8 increments WCN167ST775-001 3 WCP167ST715-002 SAMPLE AXLE WCP167ST715-003 NUMBERS WCN127ST120-004 assembly is supported and held steady during Lube change intervals as determined by the manu- removal of the spindle nut and outer bearing. facturer dictate when Level 4 service is performed. This will eliminate the possibility of spindle, bear- ing or seal damage due to the cocking or slipping NOTE: Manufacturer is defined as the final assem- of the wheel-hub assembly. bler of the product or the particular system supplier. Model: WCN When reassembling industry standard wheel-ends, ! CAUTION : Care should be taken so the wheel-end assembly is properly supported. assemble per RP 622 and RP 618. Seals and gas- Bearing Group: Inner: HM218248, Outer: HM 212049 kets must be replaced. 5. Remove adjusting nuts. Outside Diameter: 5” - Straight Tube 6. Remove outer bearing. Failed Component Analysis 7. While maintaining proper support to the wheel- Save prematurely failed parts and lube samples for Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n* end or hub, visually check lube level. In a analysis. The lubricant sample collected should be at 0.58” 25,000 lbs (normal service) 22,500 lbs (normal service) semi-fluid grease system, if the lubricant flows least four ounces. A similarly sized new lubricant sample (not previously used) is also required. This 0.75” 27,000 lbs (Normal service) 25,000 lbs (normal service) out of the hub cavity, the hub cavity should be refilled to the 3 o’clock and 9 o’clock level. This will aid in supplier assisted detection and prevention of premature failures. The components’ history of *See capacity charts for details represents 50 percent hub cavity fill. (See Figures 5 and 5A.) usage should also be provided (i.e., vehicle’s voca- tion, mileage, maintenance records, and history of Track lengths In a semi-fluid grease system, if the grease inspection and repair/replacement of components doesn’t flow, inspect lubricant condition in the such as seals, seal wear rings, lubricant, bearings, 71.5” (standard) etc.). 77.5” (standard) hub cavity. Go to Level 4 Inspection if abnormal conditions are noted. If no abnormal conditions Other tracks also available (38” to 108”) are noted, add grease until it flows out of the hub OPERATIONAL CONSIDERATIONS FOR cavity. LUBRICANTS Brakes (Refer to: Brake Lining Certification List) Service interval ranges from 100,000 miles to five 16 ½ x 7” quick change, Q, FMSI-4515E NOTE: If changing grease types or brands, years in over-the-road service, depending on axle 16½ x 7” quick change, Q+, FMSI-4707 contact your lubricant supplier to insure compat- type, manufacturer recommendations, and lubricant ibility.