ubl installation procedure for wide bushing ... - hendrickson-intl.com … · ubl installation...

TECHNICALPROCEDURETRAILER SUSPENSION SYSTEMSSUBJECT: UBL Installation Procedure For

Wide-Bushing Suspension ModelsLIT NO: L719DATE: July 2009 REVISION: A

SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IMPORTANT SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

STEP 1. — PREPARING THE SUSPENSION FOR UBL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

STEP 2. — INSTALLING THE LIFT BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Beam bottom plate has locating holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Beam bottom plate does not have locating holes — INTRAAX models . . . . . . . . . . . . . . . . . . . . . . . . .5Beam bottom plate does not have locating holes — HT models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

STEP 3. — INSTALLING THE FRAME BRACKET SUPPORT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

STEP 4. — INSTALLING THE CROSS CHANNEL OR FRAME BRACKET GUSSETS . . . . . . . . . . . . . . . . . . . . .9

STEP 5. — INSTALLING THE BRAKE CHAMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

STEP 6. — INSTALLING THE REST OF THE UBL KIT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

WELDING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

CONTROLLING THE UBL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

UBL INSTALLATION PROCEDURE — WIDE-BUSHING MODELS

2L719A

SERVICE NOTESThis publication provides under-beam lift kitinstallation instructions for Hendrickson SuspensionSystems. Before you begin:

• Read and understand all instructions andprocedures before installing any component.

• Read and observe all Caution and Warningstatements to help avoid personal injury or propertydamage.

• Follow your company’s maintenance, service,installation and diagnostic practices.

Hendrickson reserves the right to make changes andimprovements to its products and publications at anytime. Consult the Hendrickson website(www.hendrickson-intl.com) for the latest version ofthis manual.

IMPORTANT SAFETY NOTICEProper installation is important to the reliableoperation of your Hendrickson suspension. Theprocedures recommended by Hendrickson anddescribed in this publication are methods ofperforming such installation.

The warnings and cautions should be read carefullyto help prevent personal injury and to assure thatproper methods are used. Improper installation cancause damage to the vehicle and other property,personal injury, an unsafe operating condition or voidthe manufacturer’s warranty.

Carefully read, understand and follow all safetyrelated information within this publication.

EXPLANATION OF SIGNAL WORDSHazard signal words (such as Danger, Warning orCaution) appear in various locations throughout thispublication. Information accented by one of thesesignal words must be observed at all times.

Additional notes are utilized to emphasize areas ofprocedural importance and provide suggestions forease of repair. The following definitions indicate theuse of these signal words as they appear throughoutthe publication.

DANGER Indicates immediate hazards which willresult in severe personal injury or death.

WARNING Indicates hazards or unsafe practiceswhich could result in severe personalinjury or death.

CAUTION Indicates hazards or unsafe practiceswhich could result in damage tomachine or minor personal injury.

IMPORTANT An operating procedure, practice orcondition that is essential to emphasize.

WARNING: DO NOT MODIFY OR REWORKPARTS. DO NOT USE SUBSTITUTEPARTS OF THE SUSPENSION ORAXLE COMPONENTS. USE OF AMODIFIED PART OR REPLACEMENTPART NOT AUTHORIZED BYHENDRICKSON MAY NOT MEETHENDRICKSON’S SPECIFICATIONSAND CAN RESULT IN FAILURE OFTHE PART, LOSS OF VEHICLECONTROL AND POSSIBLE PERSONALINJURY OR PROPERTY DAMAGE.USE ONLY HENDRICKSONAUTHORIZED REPLACEMENT PARTS.DO NOT MODIFY PARTS WITHOUTAUTHORIZATION FROMHENDRICKSON.

CAUTION: A mechanic using a serviceprocedure or tool which has notbeen recommended by Hendricksonmust first satisfy himself that neitherhis safety nor the vehicle’s safetywill be jeopardized by the method ortool selected. Individuals deviatingin any manner from the providedinstructions assume all risks ofconsequential personal injury ordamage to equipment.

WARNING: ALWAYS WEAR PROPER EYEPROTECTION AND OTHER REQUIREDPERSONAL PROTECTIVE EQUIPMENTWHEN PERFORMING VEHICLEMAINTENANCE, REPAIR OR SERVICE.

UBL INSTALLATION PROCEDURE — WIDE BUSHING MODELS

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WARNING: Solvent cleaners can be flammable,poisonous and can cause burns. Tohelp avoid serious personal injury,carefully follow the manufacturer’sproduct instructions and guidelinesand the following procedures:

• Wear proper eye protection

• Wear clothing that protects yourskin

• Work in a well ventilated area

• Do not use gasoline, or solventsthat contain gasoline. Gasolinecan explode.

• Hot solution tanks or alkalinesolutions must be used correctly.Follow the manufacturer’srecommended instructions andguidelines carefully to helpprevent personal accident orinjury.

WELDING HARDWARE TO AXLESCAUTION When welding to or on the

suspension, take every caution toprevent bearing damage. Whengrounding welding equipment to thesuspension, prevent current frompassing through the wheel bearings.

A connection that places a wheelbearing between the ground cableconnection and the weld area candamage the bearing by electricarcing.

STEP 1. — PREPARING THE SUSPENSION FOR UBL INSTALLATION

WARNING: TO PREVENT SERIOUS EYE INJURY,ALWAYS WEAR SAFETY GLASSESWHEN PERFORMING INSTALLATIONPROCEDURES.

IMPORTANT: The under-beam lift kit (UBL) can beinstalled either before or after thesuspension is mounted to the trailer.

If the suspension intended for UBLinstallation is already installed on thetrailer, follow steps 1 through 10 belowto prepare the suspension for UBLinstallation.

If the suspension intended for UBLinstallation has not yet been installed ona trailer, follow steps 9 and 10 below toprepare the suspension for UBLinstallation.

1. Park the trailer on a level, debris-free surface.

2. Set the trailer parking brakes.

3. To prevent the trailer from moving, chock thewheels of the axle not intended for UBLinstallation.

4. Exhaust the air from the trailer suspension.

5. Release the trailer parking brakes.

6. Using a jack, raise the axle intended for UBLinstallation until the trailer wheels clear the worksurface.

7. Support the raised axle with safety stands.

WARNING: DO NOT WORK UNDER A TRAILERSUPPORTED ONLY BY JACKS. JACKSCAN SLIP OR FALL OVER,RESULTING IN SERIOUS PERSONALINJURY.

8. Remove the trailer wheels to gain access to thesuspension frame brackets and trailing arms.

9. If brake chambers are installed on thesuspension intended for UBL installation, removethem now.

10. Check the frame brackets for UBL kit clearance. AUBL kit requires 35/8 inches at the bottom of theframe brackets for installation (see figure A). Ifframe bracket gussets or a cross channelreinforcement member are installed in this 35/8inch area on the suspension intended for UBLinstallation, remove them now.

IMPORTANT: DO NOT throw away the cross channelor brake chambers if removed in the


4L719A

previous step. They will be reinstalledwith the UBL kit. If these items weredamaged during the removal process,install new replacements.

IMPORTANT: If frame bracket gussets or a crosschannel reinforcement member areinstalled but do not interfere with the35/8 inch installation requirement, thenthey do not have to be removed.

IMPORTANT: Some low-ride-height models do nothave 35/8 inches of available framebracket space on which to mount a UBLkit. If this is the case, contactHendrickson technical service at 800-455-0043 in the United States or 800-668-5360 in Canada.

11. Prepare the UBL kit components, trailing armsand frame brackets for welding. The items to bewelded must be a minimum temperature of 60ºF(16ºC) and free of moisture, dirt, rust, scale,paint and grease. Consult the assembly drawingsincluded with the UBL kit for weld area locations.

STEP 2. — INSTALLING THE LIFTBRACKET

To install the lift brackets (figure 1), accuratelyposition the bracket on the bottom of the suspensionbeam and weld in place. There are three methods foraccurately positioning the lift bracket on thesuspension beam. Your suspension model andsuspension beam bottom plate appearance (figure 2)determine which method to use for lift bracketpositioning. As shown in figure 2, look at yoursuspension beam bottom plate to determine whichmethod to use.

Newer INTRAAX suspensions have locating holes onthe suspension beam bottom plate that make easywork of lift bracket positioning.

Older INTRAAX suspensions do not have locatingholes on the suspension beam bottom plate, thereforethe template (figure 10) included in this documentmust be used to drill locating holes so the lift bracketcan be accurately positioned on the suspensionbeam.

HT model suspensions do not have locating holes onthe suspension beam bottom plate either, but the liftbrackets can be accurately positioned on thesemodels using the dimensions given in this documentand on the installation drawings.

BEAM BOTTOM PLATE HAS LOCATINGHOLES1. Install the lift bracket to the suspension beam

bottom plate with two 3/8 -16 x ¾-inchself-tapping screws from the kit. Tighten thescrews to 160-180 in. lbs. (18-20 N•m) oftorque.

UBL-001 UBL-002 and UBL-003

Sideview

Sideview

Figure 1. Lift brackets

Figure A. Checking frame brackets for UBL kit clearance

Cross channel

35/8"

In this instance, the cross channel is interfering withthe 35/8 required for UBL kit installation, so it willhave to be removed. In the image below, the same istrue of the frame bracket gussets.

35/8"

Framebracketgussets


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WARNING THE SELF-TAPPING SCREWS AREFOR BRACKET LOCATING PURPOSESONLY. THE BRACKET MUST BEWELDED AS DESCRIBED IN STEP 2.

2. Weld the lift bracket to the suspension beam witha ¼-inch fillet weld. Refer to figure 3, theinstallation drawings included with this kit, andthe WELDING PARAMETERS section of thisdocument for complete welding details.

3. Repeat steps 1 and 2 on the other suspensionbeam.

BEAM BOTTOM PLATE DOES NOT HAVELOCATING HOLES AND YOU HAVE ANINTRAAX MODEL SUSPENSION1. Position the template (figure 10) on the bottom

of the suspension beam (figure 9). Tape thetemplate in place.

2. Using a center punch and a hammer, mark thebottom of the suspension beam with two holesas shown on the template. Carefully remove thetemplate, it will be reused on the othersuspension beam.

3. Drill two 23/64-inch holes at the indicatedpositions on the suspension beam.

4. Install the lift bracket to the suspension beambottom plate with two 3/8 -16 x ¾-inchself-tapping screws from the kit. Tighten thescrews to 160-180 in. lbs (18-20 N•m) oftorque.

WARNING THE SELF-TAPPING SCREWS AREFOR BRACKET LOCATING PURPOSESONLY. THE BRACKET MUST BEWELDED AS DESCRIBED IN STEP 5.

5. Weld the lift bracket to the suspension beam witha ¼-inch fillet weld. Refer to figure 3, theinstallation drawings included with this kit, andthe WELDING PARAMETERS section of thisdocument for complete welding details.

6. Repeat steps 1 through 5 on the othersuspension beam.

BEAM BOTTOM PLATE DOES NOT HAVELOCATING HOLES AND YOU HAVE AN HTMODEL SUSPENSION1. Using the dimensions given in figure 3 view b or

view d and C-clamps or any other suitabledevice, position and temporarily clamp the liftbracket to the suspension beam.

2. Tack weld the lift bracket to the suspension beamand remove clamps.

3. Weld the lift bracket to the suspension beam witha ¼-inch fillet weld. Refer to figure 3 and theinstallation drawings for complete weldingdetails.

IMPORTANT: The holes in the lift bracket for HTmodels are not used to mount the liftbracket. DO NOT drill holes in thesuspension beam.

INTRAAX Models HT Models

NewerINTRAAX

OlderINTRAAX

Suspension beam

HT models

Examine the suspensionbeam bottom plate

Locatingholes

No locatingholes

Figure 2. Suspension beam bottom plate appearance

Use thetemplate todrilllocatingholes andpositionbrackets

No locatingholes

Use thedimensionsin thisdocumentto positionbrackets


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1"

2.5"

Figure 3. Lift bracket welding and positioning details

UBL-001 — INTRAAX Modelsview a.

4x

2x .25

UBL-001 — HT230 Modelsview b.

UBL-002 and UBL-003 — INTRAAX Modelsview c.

UBL-002 and UBL-003 — HT250T Modelsview d.

*

**

*

indicates weld placement

* = .25-inch no-weld zone

All dimensions in inches unlessotherwise shown

‡These welds are normally hiddenin this view, but are shown herefor clarity

Weld direction:

*

*

**

2x.25

4x

4x 4x2x.25

** * *Stop Start

‡

‡ ‡

‡


7L719A

STEP 3. — INSTALLING THE FRAMEBRACKET SUPPORT ASSEMBLY

To install the frame bracket support assembly (figure4), accurately position it on the frame bracket andweld in place.

Note that the frame bracket support assemblyincluded in UBL kit -001 is self locating and does notrequire measuring for placement. Simply position theself-locating ledge against the bottom of the framebracket (figure 5, view a) for correct placement.

The frame bracket support assemblies included inUBL kits -002 and -003 must be placed 35/8 inchesfrom the bottom of the frame bracket to be accuratelypositioned (figure 5, view b).

POSITIONING AND WELDING THE FRAMEBRACKET SUPPORT ASSEMBLY ON THEFRAME BRACKETNOTE: The frame bracket support assembly in UBL kit

-001 is self-locating and does not requiresteps 1 and 2 of the following procedure.

1. Measure 35/8 inches up from the bottom of theframe bracket as shown in figure 5, view b andscribe a level line across the front surface of theframe bracket.

2. Align the top edge of the frame bracket supportassembly to the line scribed in step 1.

IMPORTANT: The frame bracket support assemblymust be flush with the sides of the framebracket.

3. Temporarily clamp the frame bracket supportassembly in place and tack weld the framebracket support assembly to the frame bracket.Remove temporary clamps and verify the framebracket support assembly is properly positionedon the frame bracket.

4. Weld each side of the frame bracket supportassembly to the frame bracket with a ¼-inchfillet weld as shown in figure 5.

5. Repeat steps 1 through 4 (steps 1 and 2 notrequired if installing UBL kit -001) on the otherframe bracket.

INSTALLING THE GUSSETS1. Position gussets as shown in figure 5, .6 inches

from the bottom of the frame bracket and .6inches forward of the frame bracket front edge.Gusset must straddle the frame bracket andframe bracket support assembly as shown infigure 5.

2. Weld in place with ¼-inch fillet welds as shownin figure 5.

NOTE: Start and stop weld passes ¼ inch fromgusset ends. Fill all craters at the end of eachweld pass.

IMPORTANT: Weld gussets to both sides of the framebracket.

UBL-001 UBL-002 and UBL-003

Sideview

Sideview

Figure 4. Frame bracket support assembly

Self-locatingledge


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UBL-001view a.

UBL-002 and UBL-003view b.

Figure 5. frame bracket support assembly welding and positioning details

Self-locating ledge Bottomof framebracket

First weld,beforeinstallinggussets, 4x

First weld,beforeinstallinggussets, 4x

.25*

.6

.6†

Frame bracket Frame bracket

Gusset

Gusset

.6

.6

.25*

3.625

frame bracket support assembly must be flush withsides of frame bracket

* Install gussets only after frame bracket support assembly has been welded to frame bracket, and weld as shown, 4x

indicates weld placement

† = .25-inch no-weld zone (typical)

All dimensions in inches unless otherwise shown

Weld direction:

Scribe line here(3.625" frombottom of framebracket)

Stop Start


9L719A

STEP 4. — INSTALLING THE CROSSCHANNEL OR FRAME BRACKETGUSSETSIf your suspension has wingless frame brackets, or ifa cross channel reinforcement member or framebracket gussets were originally on the suspension butremoved during kit installation preparation, reinstallthem now.

1. Rest the cross channel on top of the framebracket support assembly as shown in figure 6.

2. Weld the cross channel to the front surface of theframe bracket with ¼-inch fillet welds as shownin figure 6.

3. Repeat step 2 on the other end of the crosschannel.

4. Obtain new frame bracket gussets. Reorient andweld to the suspension as shown in figure 6.

STEP 5. — INSTALLING THE BRAKECHAMBERSIf the brake chambers were originally on thesuspension but removed during kit installationpreparation, reinstall them now.

1. Position the brake chamber on the brakechamber mounting bracket and tighten themounting nuts to 100 - 110 ft. lbs. (136 - 149N•m) of torque.

IMPORTANT: If installing long-stroke brake chambers,it may be necessary to remove the rearself tapping screw (used in positioningthe lift bracket to the suspension beambottom plate).

2. Repeat step 1 for the other brake chamber.

STEP 6. — INSTALLING THE REST OFTHE UBL KIT COMPONENTS1. Position the beam plate assembly (figure 7) onto

the lift bracket as shown in figure 8 and attachusing the ½ -13 x 1¼-inch nuts and boltssupplied in the kit. Tighten to 55-75 ft. lbs. (75-102 N•m) of torque.

NOTE: If a gap exists between the lift bracket legs andthe “M-shaped” beam plate assembly

reinforcement, use a C-clamp to compress thelegs of the lift bracket against the beam plateassembly reinforcement so the fasteners canbe installed.

Figure 7. Beam plate assembly

Cross channel

frame bracket support assembly

.25

.252x Frame bracket

indicates weldplacement

All dimensions in inchesunless otherwise shown

INTRAAX model shown, butprocess is similar for HTmodels

Figure 6. Cross channel installation details

“M-shaped” reinforcement

1.50

1.25

Framebracketgusset

WELDING PARAMETERS28.5 volts400 IPM275-300 amps35 cfh (gas flow).045 wire

2. Repeat step 1 for the other beam plate assembly.

NOTE: Some brake chambers cannot be caged withthe UBL in place.

3. Position the actuator between the beam plateassembly and the frame bracket supportassembly as shown in figure 8 and attach usingthe 3/8 -16 x 7/8-inch bolts supplied in the kit.Tighten to 25-35 ft. lbs. (34-47 N•m) of torque.

4. Repeat step 3 for the other actuator.

4. Install the ¾ -16 nuts supplied in the kit on theair spring combo studs (stud doubles as an airinlet). Tighten to 45-55 ft. lbs. (61-75 N•m) oftorque.

5. Install air lines and the air kit for operating theunder beam lift.

6. If the suspension intended for UBL installation isalready installed on the trailer, reinstall the trailerwheels. Tighten the lug nuts to the torquerecommended by the manufacturer.


10L719A

Cent

er p

unch

and

drill

two

23/6

4 -in

ch h

oles

Figure 9. Position template on suspension beam bottom plate

Figure 8. Remaining UBL kit component installation details

Beam plate assembly

Lift bracket

½ -13 x 1¼nuts and bolts

Actuator

frame bracketsupport assembly

3/8 -16 x 7/8

bolts

¾ -16nut

All dimensions in inches unless otherwise shown

INTRAAX model shown, but component installation process is similar for HT models

Suspension beam bottom plate

Template


11L719A

Figure 10. Hole template for lift bracket positioning

Center punchand drill two23/64-inch holes

www.hendrickson-intl.com

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.C. (U.S. Rights) Hendrickson International Corporation (Rights Outside U.S.) All Rights ReservedL719 Rev A 07-09 ECN 17182

Trailer Suspension Systems250 Chrysler Drive, Unit #3Brampton, ON Canada L6S 6B6 905.789.1030Fax 905.789.1033

Trailer Suspension Systems2070 Industrial Place SECanton, OH 44707-2641 USA

866.RIDEAIR (743.3247)330.489.0045Fax 800.696.4416

Printed in United States of America

CONTROLLING THE UBLAn air control kit is required to operate the liftmechanism in running or raised mode. Refer toHendrickson publication L782, Vehicle Controls QuickReference Guide (available at www.hendrickson-intl.com), for information on selecting a lift axlecontrol kit.

Hendrickson also requires the installation of acrossover air control kit on all INTRAAX AAL andAAEDL 30K lift axle installations, along with theelimination of any quick-exhaust valve from thesuspension plumbing. This patened crossover aircontrol provides increased air volume and pressurewhen and where it is needed, and at the same timereduces the volume of air required from the reservoir.

Hendrickson MexicanaAv. Industria Automortriz #200Parque Industrial Stiva AeropuertoApodaca, N.L., México C.P. 66600 +52 (81) 8288.1300Fax +52 (81) 8288.1301

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