Hendrickson OPTIMAAX, Service Instructions Manual

Page 1: ...n 2 Section 3 Important Safety Notice 4 Section 4 Definitions 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 DiagnosticTool Software 17 Section 13 Troubleshooting Guide 21 Electronic Components...

Page 2: ...s 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 d...

Page 3: ...odule 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 ...

Page 4: ...he 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 pub...

Page 5: ...SE 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 PRIORTO SERVICE EXHAUST ALL PRESSURE IN LIFT AXLE AIR SPRINGS AND VEHICLE AIR SYSTEM BEFORE WORKING ...

Page 6: ...A 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 IFTHE AIR SPRING IS BEING REMOVED FOR AN ALTERNATE REPA...

Page 7: ...D 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 SUPPORTTHE LIFT AXLE PRIORTO SERVICING PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE FROM MOVING PRIOR TO SERVICING A LIFT A...

Page 8: ...S Controller Area Network Bus CAN Wires Controller Area Network Wires Config File License file needed to run the Diagnostic Tool Software Controlled by Hendrickson Diagnostic tool Software Software used to communicate with the lift axle ECU Electronic Control Unit EEPROM Electrically Erasable Programmable Read only Memory OBD On board Diagnostics sSAM Single Signal detection and Activation Module ...

Page 9: ...ludes Key Nos 4 7 1 4 60905 052 OPTIMAAX ECU Decal 1 5 ECU Hardware 1 6 OPTIMAAX EEPROM 1 7 OPTIMAAX Programing Decal 1 8 80860 000 Splash Shield Assembly Includes Key Nos 9 11 1 9 60905 030 Manifold Heat Warning Decal 1 10 77276 000 Splash Shield 1 11 80426 000 Air Controller Manifold 1 12 M5 x 16 mm Screw 6 13 M5 Flange Hex Nut 6 53 9 in lbs NOTE Consult the vehicle manufacturer for applicable O...

Page 10: ...er the vehicle manufacturer s specifications Harness connectors have printing A B C D E to indicate which manifold connectors to mate with The manifold is engraved with matching letters see Wiring Diagram Section of this publication The wiring harness pressure connector labeled DRIVE matches the manifold port engraved DRIVE The harness pressure connector labeled LIFT matches with the remain ing ma...

Page 11: ...12000 13000 080427 003 13000 14000 080427 004 14000 15000 080427 005 15000 16000 080427 006 16000 17000 080427 007 17000 18000 080427 008 18000 19000 THE ADDITION OF WEIGHTTOTHE VEHICLE APU AUXILIARY POWER UNIT CHAINS ETC MAY CHANGE THE CORRECT OPTIMAAX DEPLOYTHRESHOLD AND MAY REQUIRE REPLACEMENT OFTHE ECU FAILURE TO DO SO WILL OVERLOADTHE LIFT AXLE CANBUS 12V Ignition OPTIMAAX ECU OPTIMAAX Air Co...

Page 12: ...pressure sensors see Figure 8 1 in the air con troller manifold must be checked INSPECTION 1 Connect the Diagnostic Tool Software 2 Apply shop air to the drive port with a calibrated pressure gauge 3 Displayed pressure in Diagnostic Tool Software must match pressure gauge measurement within 5 PSI If not the air controller manifold must be replaced 4 Repeat Steps 2 and 3 for the lift port FIGURE 8 ...

Page 13: ... Ensure the tube ends are square free of damage and clean 5 Ensure the tube is fully inserted into the fittings tube ends are pushed past both the grip ring and the sealing O ring SUPPLY and LIFT tubes not supplied by Hendrickson AUX and DRIVE 3 8 tubes not supplied by Hendrickson 6 A spring is used to retain a mesh filter on DRIVE and SUPPLY ports These must be retained when PTC fittings are inst...

Page 14: ...ner Air Port AUX Air Port LIFT Air Port SUPPLY Air Port EXH Electrical Port A Electrical Port B Electrical Port C Air Port DRIVE Electrical Port D Electrical Port E Electrical Port DRIVE Electrical Port LIFT OPTIMAAX AIR CONTROLLER MANIFOLD AIR AND ELECTRICAL PORTS TOP VIEW FRONT VIEW BOTTOM VIEW SIDE VIEW ...

Page 15: ...ghtliner SECTION 10 Vehicle Air Plumbing Diagram Air Supply Height Control Valve Air Supply Manifold Air Signal Brake Signal Air Controller Manifold Output from Manifold Lift Spring Output from Manifold Auxiliary Ride Spring Input to Manifold Drive Suspension Pressure Drive Axle Height Control Valve ...

Page 16: ...n of the suspension It may be beneficial to weigh the vehicle to verify overload condition The OPTIMAAX system is designed to help ensure that the lift drive and steer axles operate within the proper weight parameters An overload light will indicate an overload on at least one of the axles Prior to service of the lift axle adjacent components or the air controller module a Turn ignition off b Ensu...

Page 17: ... need USB to RS232 Cable 6 26 2 00m Shielded not supplied see Figure 12 1 Manufacturer Future Technology Devices International Ltd Part Number UT232R 200 1 Locate the serial port cable typically located in the dash behind the vehicle power distribu tion module VPDM which houses the main fuse and relay center and plug into it using the USB to serial cable see Figure 12 1 2 With the ignition on and ...

Page 18: ... be more than one com port available Pick one and click Open Hendrickson OPTIMAAX Diagnostic Tool File Log Tools Help Select another COM Port untill the software opens and Select OK If the wrong COM Port is selected the software will show an Error message Hendrickson OPTIMAAX Diagnostic Tool File Log Tools Help The screen will look like this when the software is communicating with the controller C...

Page 19: ...r Freightliner FIGURE 12 5 FIGURE 12 6 Hendrickson OPTIMAAX Diagnostic Tool File Log Tools Help Digital 2 Represents the parking brake signal Hendrickson OPTIMAAX Diagnostic Tool File Log Tools Help Click on History to view ASECU current error fault codes Click here to view ASECU Log Data ...

Page 20: ...ILURE TO DO SO CAN CORRUPT INFORMATION STORED ON THE ECU Always exit and open the Diagnostic Tool Software properly 1 Prior to exiting the Diagnostic Tool Software ENGAGE the parking brake 2 Press the CLOSE button on the START tab to terminate communication with the lift axle ECU see Figure 12 7 3 Exit the window see Figure 12 7 FIGURE 12 7 Hendrickson OPTIMAAX Diagnostic Tool File Log Tools Help ...

Page 21: ... for external damage Replace wiring harness as necessary ECU is damaged Replace ECU Diagnostic Tool Software connects no ECU Current Faults reported Wiring harness is damaged connected incorrectly Verify wiring harness connection at manifold The individual solenoid connections may be incorrect Air plumbing is damaged connected incorrectly Verify air plumbing at manifold is correct and that air lin...

Page 22: ...amaged or leaking Verify PTC fittings are not leaking Manifold is damaged Replace manifold Mechanical components are damaged Refer to Troubleshooting Guide Section in Hendrickson Literature No 17730 309 Diagnostic Tool Software connects ECU Current Faults reported Damaged manifold or wiring harness Refer to Fault Codes Section below Loss of traction when axle deployed Diagnostic Tool Software conn...

Page 23: ...e if needed Lift Pressure Sensor Fault P2 Wiring harness is damaged or connected incorrectly Check wiring harness replace if needed Manifold is damaged Check manifold replace if needed Valve Block Failure Wiring harness is damaged or connected incorrectly Check wiring harness replace if needed Manifold is damaged Check manifold replace if needed CAN Failure Wiring harness is damaged or connected i...

Page 24: ...ade after the copyright date that are not reflected 17730 310 Rev A 07 18 2018 Hendrickson USA L L C All Rights Reserved Printed in United States of America Truck Commercial Vehicle Systems 1 866 755 5968 Toll free U S and Canada 800 South Frontage Road 1 630 910 2800 Outside U S and Canada Woodridge IL 60517 4904 USA Fax 1 630 910 2899 ...