Hendrickson OPTIMAAX Service Instructions Manual
TABLE OF CONTENTS
OPTIMAAX® Lift Axle System
Air Controller Module for
Freightliner Vehicles
SUBJECT: Service Instructions
LIT NO: 17730-310
DATE: July 2018 REVISION: A
Section 1 Introduction ......................2
Section 2 Product Description ...............2
Section 3 Important Safety Notice ............4
Section 4 Denitions .......................8
Section 5 Parts List .........................9
Section 6 Air Controller Module ............ 10
Section 7 Wiring Diagram ................. 11
Section 8 Preventive Maintenance .......... 12
Section 9 Air Controller Manifold Diagram ... 13
Section 10 Vehicle Air Plumbing Diagram .... 15
Section 11 System Operation ............... 16
Section 12 Diagnostic Tool Software ......... 17
Section 13 Troubleshooting Guide ........... 21
Electronic Components ............. 21
Fault Codes ...................... 23
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
SECTION 1
Introduction
This publication is intended to acquaint and assist maintenance personnel in the preventive
maintenance, service, repair and rebuild of the air controller module for Hendrickson’s OPTIMAAX
Lift Axle System for Freightliner vehicles.
NOTE Use only Hendrickson genuine parts for servicing this system.
Alteration of the OPTIMAAX system air controller module is not permitted.
It is important to read and understand the entire Technical Procedure publication prior to installation or performing any maintenance, service, repair, or rebuild of this product. The information
in this publication contains parts lists, safety information, product specifications, features, proper
maintenance, service, repair and rebuild instructions for the OPTIMAAX system air controller.
Hendrickson reserves the right to make changes and improvements to its products and publications
at any time. Contact Hendrickson Truck Tech Services for information on the latest version of this
manual at 1-866-755-5968 (toll-free U.S. and Canada), 1-630-910-2800 (outside U.S. and
Canada) or e-mail: truckparts@hendrickson-intl.com.
SECTION 2
Product Description
Hendrickson’s OPTIMAAX system is a 6 × 2 solution to help fleets save fuel cost, tire wear and
weight with comparable handling to 6 × 4 tandem axle configurations. Operating as a liftable
axle in the forward tandem position, this system provides versatility for fleets with variable loads.
The OPTIMAAX system air controller monitors air pressure in the drive axle suspension, and calculates axle load based on air pressure levels. When load reaches a set threshold (programmed by
Hendrickson, where the limiting factor is typically steer axle load) the OPTIMAAX lift axle automatically deploys. The OPTIMAAX system air controller module includes the air controller manifold,
electronic control unit (ECU), and the wiring harness (supplied by Freightliner).
Proprietary program logic controls lift axle movement, load transfer and braking functions.
■
Fully automated controls — Eliminates driver intervention versus conventional 6x2 manual
control systems. Automates axle lowering and lifting by sensing load capacities.
■
Optimized traction and handling — Lifted axle position provides increased traction by
increasing drive axle load. Improved traction when backing under trailers in soft soil or wet
conditions versus traditional 6 x 2 configuration. Maintains vehicle handling characteristics by
keeping the drive axle behind the fifth wheel.
®
Introduction 2 17730-310
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
FIGURE 2-1 Air Controller Manifold
FIGURE 2-2 Electronic Control Unit (ECU)
FIGURE 2-3 Air Controller Wiring Harness (Supplied by Freightliner)
Freightliner Part No. A06-95715
HARN-AXLE-LIFT, CHAS, HDR
Freightliner Part No. A06-95709
HARN-AXLE-LIFT, DASH, HDR, P4
17730-310 3 Product Description
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
SECTION 3
Important Safety Notice
Proper maintenance, service, and repair is important for the reliable operation of the suspension.
The procedures recommended by Hendrickson and described in this technical publication are
methods of performing such maintenance, service and repair.
This technical publication should be read carefully to help prevent personal injury and to assure
that proper methods are used. Improper maintenance, service or repair may damage the vehicle,
cause personal injury, render it unsafe in operation, or void manufacturer’s warranty.
Failure to follow the safety precautions in this manual can result in personal injury and / or property damage. Carefully read and understand all safety related information within this publication,
on all decals and in all such materials provided by the vehicle manufacturer before conducting
any maintenance, service or repair.
■
EXPLANATION OF SIGNAL WORDS
Hazard “Signal Words” (Danger-Warning-Caution) appear in various locations throughout this
publication. Information accented by one of these signal words must be observed to help minimize the risk of personal injury to service personnel, or possibility of improper service methods
which may damage the vehicle or render it unsafe.
This is the safety alert symbol. It is used to alert you to potential personal injury haz-
ards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
Additional Notes or Service Hints are utilized to emphasize areas of procedural importance and
provide suggestions for ease of repair. The following definitions indicate the use of these signal
words as they appear throughout the publication.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN SERIOUS
INJURY OR DEATH.
INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN SERIOUS
INJURY OR DEATH.
INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR
MODERATE INJURY, OR PROPERTY DAMAGE.
NOTE An operating procedure, practice condition, etc. which is essential to emphasize.
SERVICE HINT A helpful suggestion that will make the servicing being performed a little easier and / or faster.
Also note that particular service operations may require the use of special tools designed for
specific purposes. These special tools can be found in the Special Tools Section of this publication.
The torque symbol alerts you to tighten fasteners to a specified torque value. Refer to Torque
Specifications Section of this publication.
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 may damage the vehicle,
cause personal injury, render the vehicle unsafe in operation, or void manufacturer’s warranty.
Important Safety Notice 4 17730-310
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
■
SAFETY PRECAUTIONS
NOTE REPLACE ANY SAFETY DECALS THAT ARE FADED, TORN, MISSING, ILLEGIBLE, OR OTHERWISE
DAMAGED. CONTACT HENDRICKSON TO ORDER REPLACEMENT LABELS.
LIFT AXLE RAPID AUTOMATIC MOVEMENT
FIGURE 3-1 Product / Safety Decal 60905-048
LIFT AXLE RAPID, AUTOMATIC MOVEMENT CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.
THE LIFT AXLE CONTROL SYSTEM IS PROGRAMMED TO
AUTOMATICALLY:
LOWER THE LIFT AXLE IF –
■
A LOAD ON THE PRIMARY REAR SUSPENSION
IS ABOVE A PRESET VALUE, OR
■
THE PARKING BRAKE IS ENGAGED, OR
■
THE IGNITION SWITCH IS OFF, OR
■
A MAJOR SYSTEM FAULT IS DETECTED
RAISE THE LIFT AXLE IF –
■
1) THE PARKING BRAKE IS DISENGAGED,
AND 2) A LOAD ON THE PRIMARY REAR
SUSPENSION IS BELOW A PRE-SET VALUE.
LIFT AXLE LOADING / UNLOADING
■
ENSURE ALL PERSONNEL ARE CLEAR OF LIFT AXLE
DURING VEHICLE LOADING / UNLOADING AND
OPERATION.
■
ENGAGE THE PARKING BRAKE DURING VEHICLE
LOADING / UNLOADING.
PRIOR TO SERVICE
■
EXHAUST ALL PRESSURE IN LIFT AXLE AIR SPRINGS AND VEHICLE AIR SYSTEM BEFORE WORKING
ON OR AROUND LIFT AXLE.
■
REMOVE 15 AMP FUSE FROM F15 LOCATION, REFER TO THE SYSTEM OPERATION SECTION OF
THIS PUBLICATION.
AIR CONTROLLER MANIFOLD
HOT AIR CONTROLLER MANIFOLD SURFACE CAN CAUSE BURNS. DO NOT TOUCH. ALLOW MANIFOLD TO
COOL BEFORE SERVICING, SEE FIGURES 3-2 AND 3-3.
FIGURE 3-2 FIGURE 3-3
ELECTRICAL SYSTEM
DO NOT WORK ON THE VEHICLE ELECTRICAL SYSTEM WITH THE VEHICLE POWER ON. DAMAGE TO
VEHICLE ELECTRICAL SYSTEM AND / OR UNEXPECTED AXLE MOVEMENT MAY RESULT.
17730-310 5 Important Safety Notice
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
WIRING HARNESS
ENSURE THERE IS SUFFICIENT FREE MOVEMENT IN AIR CONTROLLER WIRING HARNESS TO PREVENT
WIRES AND CONNECTIONS FROM BEING UNDER TENSION DURING INSTALLATION. FAILURE TO DO SO
MAY DAMAGE OR FRAY THE CABLES.
SYSTEM INSTALLATION
IT IS THE RESPONSIBILITY OF THE INSTALLER OF THE AIR CONTROLLER MODULE AND OTHER OPTIMAAX
SYSTEM COMPONENTS TO ENSURE PROPER INSTALLATION. ANY INSTALLATION DEVIATIONS MUST
BE APPROVED, IN WRITING, BY HENDRICKSON’S PRODUCT ENGINEERING DEPARTMENT. ANNUAL
INSPECTION OF SYSTEM PRESSURE SENSORS IS REQUIRED TO CHECK FOR PROPER LOADING ON
DRIVE AXLE AND STEER AXLE. FAILURE TO COMPLY WITH ANY OF THE ABOVE WILL VOID APPLICABLE
WARRANTIES.
AIR SPRING INFLATION AND DEFLATION
PRIOR TO DISASSEMBLY OF THE SUSPENSION, AIR SPRING ASSEMBLIES MUST BE DEFLATED.
UNRESTRICTED AIR SPRING ASSEMBLIES CAN VIOLENTLY SHIFT. DO NOT INFLATE AIR SPRING
ASSEMBLIES WHEN THEY ARE UNRESTRICTED. AIR SPRING ASSEMBLIES MUST BE RESTRICTED
BY SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE BEYOND PRESSURES
RECOMMENDED BY AIR SPRING MANUFACTURER, CONTACT HENDRICKSON TECHNICAL SERVICES
FOR DETAILS. IMPROPER USE OR OVER INFLATION MAY CAUSE AIR SPRING ASSEMBLIES TO BURST,
CAUSING PROPERTY DAMAGE AND / OR SEVERE PERSONAL INJURY.
PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM, ENSURE ALL
PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND AROUND THE SERVICE
AREA, FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.
AIR SPRING INFLATION
INFLATE THE SUSPENSION SLOWLY AND MAKE SURE THE RUBBER BLADDER OF THE AIR SPRING
INFLATES UNIFORMLY AND IS NOT BINDING. FAILURE TO DO SO CAN CAUSE DAMAGE TO THE AIR
SPRING AND / OR MOUNTING BRACKETS AND VOID WARRANTY.
AIR SPRING LOWER MOUNTING STUDS
IF THE AIR SPRING IS BEING REMOVED FOR AN ALTERNATE REPAIR, IT IS MANDATORY TO LUBRICATE THE
LOWER AIR SPRING FASTENERS WITH PENETRATING OIL AND REMOVE WITH HAND TOOLS TO PREVENT
DAMAGE TO THE LOWER AIR SPRING MOUNTING STUD. FAILURE TO DO SO CAN CAUSE COMPONENT
DAMAGE AND VOID WARRANTY.
PROCEDURES AND TOOLS
A MECHANIC USING A SERVICE PROCEDURE OR TOOL WHICH 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 INSTRUCTIONS PROVIDED ASSUME ALL RISKS OF POTENTIAL PERSONAL INJURY OR
DAMAGE TO EQUIPMENT INVOLVED.
PERSONNEL PROTECTIVE EQUIPMENT
ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT
TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTENANCE, REPAIR OR SERVICE.
MODIFYING COMPONENTS
DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON. DO NOT
SUBSTITUTE REPLACEMENT COMPONENTS NOT AUTHORIZED BY HENDRICKSON. USE OF MODIFIED,
REWORKED, SUBSTITUTE OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY NOT
MEET HENDRICKSON’S SPECIFICATIONS, AND CAN RESULT IN FAILURE OF THE PART, ADVERSE VEHICLE
HANDLING, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE, AND WILL VOID ANY APPLICABLE
WARRANTIES. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.
Important Safety Notice 6 17730-310
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
SUPPORT THE VEHICLE PRIOR TO SERVICING
PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE
FROM MOVING. PRIOR TO SERVICING A VEHICLE IN THE RAISED POSITION, PROPERLY SUPPORT THE
VEHICLE WITH SAFETY STANDS. DO NOT WORK AROUND OR UNDER A RAISED VEHICLE SUPPORTED
ONLY WITH FLOOR JACKS OR OTHER LIFTING DEVICES, FAILURE TO DO SO CAN CAUSE DEATH,
PERSONAL INJURY OR DAMAGE TO COMPONENTS.
IMPROPER JACKING METHOD
IMPROPER JACKING METHOD CAN CAUSE STRUCTURAL DAMAGE AND RESULT IN ADVERSE VEHICLE
HANDLING, SEVERE PERSONAL INJURY OR DEATH. DO NOT USE AXLE BEAM OUTBOARD OF AXLE
SPRING SEATS. REFER TO VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.
SUPPORT THE LIFT AXLE PRIOR TO SERVICING
PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE
FROM MOVING. PRIOR TO SERVICING A LIFT AXLE IN THE RAISED POSITION, (1) PROPERLY SUPPORT
THE LIFT AXLE WITH SAFETY STANDS, AND (2) RELEASE ALL AIR PRESSURE IN THE LIFT AXLE AIR
SPRINGS AND RIDE SPRINGS. DO NOT WORK AROUND OR UNDER A RAISED LIFT AXLE SUPPORTED
ONLY WITH FLOOR JACKS OR OTHER LIFTING DEVICES, FAILURE TO DO SO CAN CAUSE DEATH,
PERSONAL INJURY OR DAMAGE TO COMPONENTS.
17730-310 7 Important Safety Notice
OPTIMAAX® Lift Axle System Air Controller Module for Freightliner
SECTION 4
Definitions
DEFINITIONS
APU
Bobtail Condition
CAN BUS
CAN Wires
Cong File
Diagnostic tool
Software
ECU
EEPROM
OBD
sSAM
USB
VPDM
Auxiliary Power Unit
A bobtail truck is a semi-truck that travels from one point to another
without a trailer.
Controller Area Network Bus
Controller Area Network Wires
License le needed to run the Diagnostic Tool Software. Controlled
by Hendrickson.
Software used to communicate with the lift axle
Electronic Control Unit
Electrically Erasable Programmable Read-only Memory
On-board Diagnostics
Single Signal-detection and Activation Module
Universal Serial Bus
Vehicle Power Distribution Module
Denitions 8 17730-310
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