Hendrickson PRIMAAX EX Technical Procedures

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TABLE OF CONTENTS

Section 1
. . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2
Section 3
Section 4
Section 5
. . . . . . . . . . . . . . . . . . . . . . . . . 12
PRIMAAX EX . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRIMAAX . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 6
Areas of Inspection . . . . . . . . . . . . . . . . . . . 16
Component Inspection . . . . . . . . . . . . . . . . 18
U-bolt Fasteners . . . . . . . . . . . . . . . . . . . . . 19
Transverse Torque Rods . . . . . . . . . . . . . . . . 20
Longitudinal Torque Rods . . . . . . . . . . . . . . 20
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . 21
Air Fitting Inspection . . . . . . . . . . . . . . . . . . 22
Section 7
Ride Height Adjustment . . . . . . . . . . . . . . . . 23
Lateral Alignment . . . . . . . . . . . . . . . . . . . . 23
Axle Pinion Angle . . . . . . . . . . . . . . . . . . . . 24
(Scrub Angle) . . . . . . . . . . . . . . . . . . . . . . . 24
Pinion Angle Adjustment . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . 16
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PRIMAAX
EX / PRIMAAX
®
Volvo Vehicles
SUBJECT: Service Instructions
LIT NO: 17730-254
DATE: March 2012
Section 8
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Height Control Valve . . . . . . . . . . . . . . . . . . 29
Air Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . 31
Transverse Torque Rod . . . . . . . . . . . . . . . . . 32
Longitudinal Torque Rod . . . . . . . . . . . . . . . 32
Longitudinal Torque Rod Bushing . . . . . . . . . 33
U-beam Assembly . . . . . . . . . . . . . . . . . . . . 35
D-pin Bushing . . . . . . . . . . . . . . . . . . . . . . . 38
QUIK-ALIGN Pivot Bushing . . . . . . . . . . . . . . 43
Top Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bottom Cap and Axle Spacer . . . . . . . . . . . . 47
Axle Stops . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Frame Hanger . . . . . . . . . . . . . . . . . . . . . . 50
Section 9
PRIMAAX EX . . . . . . . . . . . . . . . . . . . . . . . . . 54
PRIMAAX . . . . . . . . . . . . . . . . . . . . . . . . . . 56
for
®
REVISION: B
. . . . . . . . . . . 29
. . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . 58

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Summary of Contents for Hendrickson PRIMAAX EX

  • Page 1: Table Of Contents

    Longitudinal Torque Rod Bushing ..33 PRIMAAX EX ......12 Support Beam Assembly and Cross Tube .
  • Page 2: Introduction

    Hendrickson reserves the right to make changes and improvements to its products and publications at any time. Contact Hendrickson Tech Services for information on the latest ver- sion of this manual at 1-866-755-5968 (toll-free U.S. and Canada), 630-910-2800 (outside U.S.
  • Page 3 Site travel ratings are consistent with specifications and must not be exceeded. 2. Axle travel may be limited by vehicle manufacturer; axle stop settings may restrict suspension’s articulation. 3. For different ride height options, please contact Hendrickson, your vehicle manufacturer or authorized vehicle dealer for further information.
  • Page 4: Important Safety Notice

    Important Safety Notice Proper maintenance, service and repair are important to the reliable operation of the suspen- sion. The procedures recommended by Hendrickson and described in this technical publication are methods of performing such maintenance, service and repair. The warnings and cautions should be read carefully to help prevent personal injury and to assure that proper methods are used.
  • Page 5 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, LOSS OF VEHICLE CONTROL, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE, AND WILL VOID WARRANTY.
  • Page 6 SHOCK ABSORBERS REMAIN CONNECTED. FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO SEPARATE FROM THE PISTON AND RESULT IN PREMATURE AIR SPRING FAILURE. REPLACEMENT OF SHOCK ABSORBERS WITH NON-HENDRICKSON PARTS CAN ALTER THE REBOUND TRAVEL OF THE SUSPENSION.
  • Page 7 ® TRANSVERSE TORQUE RODS PRIMAAX EX / PRIMAAX SUSPENSIONS INCORPORATE TRANSVERSE RODS FOR VEHICLE STABILITY. IF THESE COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL, THE VEHICLE SHOULD NOT BE OPERATED. FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING, LOSS OF VEHICLE CONTROL, POSSIBLE TIRE CONTACT WITH THE FRAME, PREMATURE COMPONENT DAMAGE, OR SEVERE PERSONAL INJURY.
  • Page 8 PROCEDURES AND TOOLS A TECHNICIAN 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 WILL ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED.
  • Page 9: Special Tools

    Special Tools These shop made tools are designed to install and remove pivot bushing and D-Pin bushing. Bushing tools are made from cold rolled steel or equivalent. Drawings are for reference only. Hendrickson does not supply these tools. 17730-254 Special Tools...
  • Page 10 Hendrickson PRIMAAX EX QUIK-ALIGN Socket Tool is available from the Owatonna Tool Corporation (Owatonna Tool No. 1767, website: www.otctools.com) or a shop made tool can be made from the drawing shown. Hendrickson does not supply QUIK-ALIGN tooling. Material: Optional per customer discretion, Grade 80 or better case harden per SAE requirements.
  • Page 11 Due to some vehicle configurations and/or tire sizes wheel removal may be required. Use the OTC Quick Wrench tool with Hendrickson PRIMAAX EX / PRIMAAX suspension lon- gitudinal torque rod to top pad configuration illustrated in Figure 4-2 and with PRIMAAX suspensions detachable end cap, see Figure 4-3.
  • Page 12: Parts Lists

    SECTION 5 Parts Lists PRIMAAX EX Parts Lists 17730-254...
  • Page 13 NOTE: * Quantities shown are for a tandem confi guration. ** Item Required, component supplied by vehicle manufacturer. Hendrickson is not responsible for components not supplied by Hendrickson, for assistance with maintenance and rebuild instructions on these components see vehicle manufacturer.
  • Page 14: Primaax

    PRIMAAX for Volvo Vehicles ® PRIMAAX Parts Lists 17730-254...
  • Page 15 ** Item Required, component supplied by Vehicle Manufacturer. Hendrickson is not responsible for components not supplied by Hendrickson, for assistance with maintenance and rebuild instructions on these components see vehicle manufacturer. *** No longer available for service, see replacement guide below. For more information, refer to Hendrickson Technical Bulletin SEU-0229 or contact Hendrickson Tech Services.
  • Page 16: Preventive Maintenance

    PRIMAAX EX • PRIMAAX suspension system and component parts function to their highest efficiency. NOTE Torque values shown in this publication apply only if Hendrickson supplied fasteners are used. If non Hendrickson fasteners are used, follow the torque specification listed in the vehicle manufacturer’s service manual.
  • Page 17 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® FIGURE 6-1 FIGURE 6-2 INSPECTION AT 1,000 MILES 1. Visually inspect suspension components with special attention to air springs and U-beam assembly (support beam assembly, cross tube, and integrated end cap). Check for: Proper suspension function Any signs of unusual movement, loose or missing components Any signs of abrasive or adverse contact with other components...
  • Page 18: Component Inspection

    ® ® PREVENTIVE MAINTENANCE – PRIMAAX EX • PRIMAAX Off highway and severe service – Every 25,000 miles or six months, whichever comes first 100% On-highway – Every 50,000 miles or 12 months, whichever comes first 1. Visually inspect suspension components with special attention to air springs and U-beam Assembly (support beam assembly, cross tube, and integrated or detachable end cap).
  • Page 19: U-Bolt Fasteners

    100% On-highway – Every 50,000 miles or 12 months, whichever comes first NOTE Current Hendrickson Truck Suspension Systems U-bolt clamp group hardware for the PRIMAAX EX / PRIMAAX suspensions are ¾"-16 UNF Grade C locknuts and ¾"-16 UNF Grade 8 U-bolts which are phosphate and oil coated.
  • Page 20: Transverse Torque Rods

    Method 2 — with the vehicle shut down, a lever check can be made with a long pry bar placed under each rod end and pressure applied. NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts for all straddle mount torque rod attachments. Preventive Maintenance...
  • Page 21: Shock Absorber

    Straddle Mount Tapered Stud SHOCK ABSORBER Hendrickson uses a long service life, premium shock absorber on all PRIMAAX EX / PRIMAAX suspensions. If shock absorber replacement is necessary, Hendrickson recommends that the shock absorbers be replaced with identical Hendrickson Genuine parts for servicing. Failure to do so will affect the suspension performance, durability, and will void the warranty.
  • Page 22: Air Fitting Inspection

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® VISUAL INSPECTION Look for these potential problems when doing a visual inspection. Inspect the shock absorbers fully extended. Replace as necessary. FIGURE 6-9 LEAKING VS. MISTING SHOCK VISUAL INSPECTION The inspection must not be conducted after driving in wet weather or a vehicle wash. Shocks needs to be free from water.
  • Page 23: Alignment & Adjustments

    The Volvo PRIMAAX EX / PRIMAAX suspension is equipped with a height control valve located on the front drive axle. The height control valve is not supplied by Hendrickson, although it is a required component. Hendrickson is not responsible for components supplied by the vehicle manufacturer.
  • Page 24: Axle Pinion Angle

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® AXLE PINION ANGLE FIGURE 7-1 Drive axle pinion angles are established by the vehicle manufacturer. The suspension axle brackets called out in the Pinion Angle Chart in the Parts Lists Section of this publication, are machined to specific angles to meet the vehicle manufac- turer specified requirements.
  • Page 25 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® proper alignment instructions for the PRIMAAX  EX • PRIMAAX suspension model as determined by the ride height of the suspension. NOTE Since the remaining drive axle(s) will be aligned relative to the front drive axle, it is essential that the front drive axle is aligned within the vehicle manufacturer’s specifications prior to the alignment of the remaining drive axle(s).
  • Page 26: Alignment Adjustment Instructions

    Contact the vehicle manufacturer for specifications. DO NOT ASSEMBLE THE QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY HENDRICKSON H-COATED FASTENERS TO SUSTAIN THE PROPER CLAMP FORCE. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY. ENSURE THAT...
  • Page 27 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® NOTE Use a new QUIK-ALIGN pivot bolt kit (see Parts Lists Section of this publication) for any axle alignment or disassembly of the QUIK-ALIGN connection. This ensures that the proper clamp load is applied to the connection, so that the joint will not slip in service.
  • Page 28: Pinion Angle Adjustment

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® PINION ANGLE ADJUSTMENT ADJUSTMENT OF 1.5 DEGREES OR LESS FIGURE 7-6 NOTE When correcting the pinion angle of an axle the correction must be in equal amounts on both sides of the axle. However, the total number of shims per side may differ due to axle alignment.
  • Page 29: Component Replacement

    HEIGHT CONTROL VALVE The height control valve is not supplied by Hendrickson, although it is a required component. Hendrickson is not responsible for components supplied by the vehicle manufacturer. For assis- tance with inspection, adjustments, maintenance, replacement and rebuild instructions on these components see vehicle manufacturer.
  • Page 30 3. Install the air spring between the frame and cross tube. a. PRIMAAX EX — Ensure the slot in the bottom of the air spring engages the “beam notch” on the top of the beam, see Figure 8-1.
  • Page 31: Shock Absorber

    ABSORBERS REMAIN CONNECTED. FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO SEPARATE FROM THE PISTON AND RESULT IN PREMATURE AIR SPRING FAILURE. REPLACEMENT OF SHOCK ABSORBERS WITH NON-HENDRICKSON PARTS CAN ALTER THE REBOUND TRAVEL OF THE SUSPENSION. DISASSEMBLY 1.
  • Page 32: Transverse Torque Rod

    1. Install the torque rod. 2. Install the mounting fasteners and any shims that were removed. NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts be used for all torque rod attachments. NOTE It is mandatory to have the vehicle at proper ride height prior to tightening the ¾" straddle bushing and the ⁄...
  • Page 33: Longitudinal Torque Rod Bushing

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® 3. Tighten all fasteners to the required specification, see Torque Specifications Section of this publication, see Figure 8-3. 4. When assembly is complete check the drive axle pinion angles, see Alignment & Adjust- ments Section of this publication.
  • Page 34: Support Beam Assembly And Cross Tube

    U-beam assembly service kits part number 60961-235 (forward) and 60961-236 (rear), see Figure 8-9, must be used for any necessary replacement of PRIMAAX only support beam assemblies in the field. Refer to Hendrickson Technical Bulletin SEU-0229 for more information. Component Replacement...
  • Page 35: U-Beam Assembly

    U-BEAM ASSEMBLY IMPORTANT NOTICE As of April 2010, Hendrickson introduced new U-beam assembly enhancements for PRIMAAX EX suspensions to be equipped on new production vehicles and for aftermarket U-beam assembly kits. The new enhancements to the U-beam assembly result in a maintenance-free integrated end cap connection.
  • Page 36 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® FIGURE 8-10 THE USE OF A FLOOR JACK EQUIPPED WITH A FOUR INCH SUPPORT PLATE IS MANDATORY TO SUPPORT THE SUPPORT BEAM AND CROSS TUBE U-BEAM ASSEMBLY. DO NOT USE A BOTTLE JACK. THE USE OF A BOTTLE JACK WILL NOT ENGAGE THE CROSS TUBE TO FACILITATE SAFE LOWERING AND RAISING OF THE SUPPORT BEAMS AND CROSS TUBE U-BEAM ASSEMBLY.
  • Page 37 AT REMOVAL AND INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS. 3. Install the U-beam assembly into the hangers. DO NOT ASSEMBLE ANY QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY HENDRICKSON COATED FASTENERS TO SUSTAIN THE PROPER CLAMP FORCE. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY AND VOID WARRANTY.
  • Page 38: D-Pin Bushing

    275-325 foot pounds torque, see Figure 8-11.. 11. Install the air spring between the frame and cross tube. PRIMAAX EX — Ensure the slot in the bottom of the air spring engages the “beam notch” on the top of the beam, see Figure 8-12.
  • Page 39 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® NOTE On PRIMAAX EX models built after September 2010 or equipped with the enhanced U-beam Assembly, it will be necessary to remove the existing sealant and tamper resistant cap for the support beam/cross tube connection to proceed with the bolt removal. Carefully remove sealant with a hand scraper to prevent damage to the U-beam assembly.
  • Page 40 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® FIGURE 8-14 FIGURE 8-15 12. Push directly on the D-pin Removal Tool until the D-Pin bushing is pressed out of the sup- port beam bore. 13. Clean the support beam bore with a wire wheel. Inspect the inner diameter of the D-Pin bore on the support beam, check for any damage to the support beam bore, replace as necessary.
  • Page 41 ® ® DO NOT ASSEMBLE ANY QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY HENDRICKSON COATED FASTENERS TO SUSTAIN THE PROPER CLAMP FORCE. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY AND VOID WARRANTY.
  • Page 42 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® FIGURE 8-21 15. Tighten the ⁄ " cross tube retaining bolt head to 525-575 foot pounds torque. 16. Tighten D-Pin locknuts to 275-325 foot pounds torque and remove the cross tube support.
  • Page 43: Quik-Align Pivot Bushing

    DO NOT allow the sealant to interfere with air spring mounting. 22. Install the air spring between the frame and cross tube. PRIMAAX EX — Ensure the slot in the bottom of the air spring engages the “beam notch” on the top of the beam.
  • Page 44: Top Pad

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® FIGURE 8-24 FIGURE 8-25 ASSEMBLY NOTE DO NOT use petroleum or soap base lubricant, it can cause an adverse reaction with the bushing material, such as deterioration. 1. Lubricate the bushing and the inner diameter of the support beam eye with light Naphthenic Base Oil, such as 60 SUS at...
  • Page 45 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® SOME VEHICLE APPLICATIONS, SUCH AS VEHICLES EQUIPPED WITH OUTRIGGERS, RETAIN SOME PRESSURE IN THE AIR SPRINGS AT ALL TIMES. PRIOR TO PERFORMING ANY MAINTENANCE, SERVICE, OR REPAIR OF THE SUSPENSION, VERIFY EACH AIR SPRING IS COMPLETELY DEFLATED. FAILURE TO DO SO COULD RESULT IN SERIOUS PROPERTY DAMAGE AND/OR SEVERE PERSONAL INJURY.
  • Page 46 2. Install new U-bolts, washers, and locknuts. NOTE Current Hendrickson U-bolt locknuts for the PRIMAAX EX / PRIMAAX suspension are ¾"-16 UNF Grade C and are phosphate and oil coated. 3. Verify that the U-bolts are seated properly in the channels of the top pad.
  • Page 47: Bottom Cap And Axle Spacer

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® BOTTOM CAP AND AXLE SPACER NOTE It is not necessary to loosen the QUIK-ALIGN connection to service the bottom cap and axle spacer, therefore alignment is preserved during service. If the QUIK-ALIGN connection is loosened during service, alignment is required after service is completed.
  • Page 48 NOTE Current Hendrickson Truck Suspension Systems U-bolt locknuts for the PRIMAAX EX / PRIMAAX suspension are ¾"-16 Grade C and are phosphate and oil coated. 4. Install the U-bolt ¾" washers and the locknuts and hand tighten, DO NOT tighten to torque at this time.
  • Page 49 " locknuts to 200-225 foot pounds torque. 14. Install the air spring between the frame and the cross tube. PRIMAAX EX: Ensure the slot in the bottom of the air spring engages the notch on the top of the beam.
  • Page 50: Axle Stops

    PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® 15. Install the lower air spring mounting bracket around the cross tube, engaging the mounting studs on the air Spring. Using HAND TOOLS install the lower mounting fasteners and tighten 20-30 foot pounds torque. 16.
  • Page 51 DO NOT ASSEMBLE ANY QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY HENDRICKSON DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN THE PROPER CLAMP FORCE. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY AND VOID WARRANTY.
  • Page 52 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® NOTE Use a new support beam QUIK-ALIGN Bolt Kit (see Parts List Section of this publication) for any axle alignment or disassembly of the QUIK-ALIGN connection. This ensures that the proper clamp load is applied to the connections, so that the joints will not slip in service.
  • Page 53 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® 17730-254 Component Replacement...
  • Page 54: Torque Specifications

    SECTION 9 Torque Specifications PRIMAAX EX HENDRICKSON RECOMMENDED TORQUE VALUES PROVIDED IN FOOT POUNDS Torque Specifi cations 17730-254...
  • Page 55 * Quantities shown are per axle. Double for tandem, triple for tridem. ** Torque values shown apply only if Hendrickson supplied fasteners are used. If non Hendrickson fasteners are used, follow the torque specifi cation listed in vehicle manufacturer’s service manual.
  • Page 56: Primaax

    PRIMAAX for Volvo Vehicles ® PRIMAAX HENDRICKSON RECOMMENDED TORQUE VALUES PROVIDED IN FOOT POUNDS Torque Specifi cations 17730-254...
  • Page 57 * Quantities shown are per axle. Double for tandem, triple for tridem. ** Torque values shown apply only if Hendrickson supplied fasteners are used. If non Hendrickson fasteners are used, follow the torque specifi cation listed in vehicle manufacturer’s service manual.
  • Page 58: Section 10 Troubleshooting Guide

    EX / PRIMAAX for Volvo Vehicles ® ® SECTION 10 Troubleshooting Guide PRIMAAX EX • PRIMAAX TROUBLESHOOTING GUIDE CONDITION POSSIBLE CAUSE CORRECTION Air spring not infl ated to Repair air system and check ride height. See Ride Height Adjustment in the Alignment specifi cation or damaged &...
  • Page 59 PRIMAAX EX / PRIMAAX for Volvo Vehicles ® ® PRIMAAX EX • PRIMAAX TROUBLESHOOTING GUIDE (CONT.) CONDITION POSSIBLE CAUSE CORRECTION Suspension is overloaded Redistribute load to correct weight. Air Spring leaking or damaged Replace air spring. Inspect air fi ttings, see Air Fitting Inspection in the Preventive Maintenance Section of Leak in air system this publication.
  • Page 60 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 refl ected. 17730-254 Rev B 03-12 © 2012 Hendrickson USA, L.L.C. (U.S. Rights) Hendrickson International Corporation (Rights Outside U.S.) All Rights Reserved Printed in United States of America...

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