Hendrickson OPTIMAAX Service Instructions Manual
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Hendrickson OPTIMAAX Service Instructions Manual

Lift axle system air controller module for freightliner vehicles
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TABLE OF CONTENTS

Section 1
. . . . . . . . . . . . . . . . . . . . . .2
Section 2
Section 3
Section 4
. . . . . . . . . . . . . . . . . . . . . . .8
Section 5
. . . . . . . . . . . . . . . . . . . . . . . . .9
Section 6
Section 7
Section 8
. . . . . . . . . . . . . . .2
. . . . . . . . . . . .4
. . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . 11
. . . . . . . . . . 12
OPTIMAAX
Lift Axle System
®
Air Controller Module for
Freightliner Vehicles
SUBJECT: Service Instructions
LIT NO: 17730-310
DATE: July 2018
Section 9
Electronic Components . . . . . . . . . . . . . 21
Fault Codes . . . . . . . . . . . . . . . . . . . . . . 23
REVISION: A
. . . 13
. . . . 15
. . . . . . . . . . . . . . . 16
. . . . . . . . . 17
. . . . . . . . . . . 21

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  • Page 1: 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 TABLE OF CONTENTS Section 1 Introduction Section 9 Air Controller Manifold Diagram . . . . . . . . . . . . . . . . . . . . . .2 .

  • Page 2: Introduction

    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 .

  • Page 3: Figure

    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...

  • Page 4: Important Safety Notice

    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 .
  • Page 5 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 .
  • Page 6 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 .
  • Page 7 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 .

  • Page 8: Definitions

    Controller Area Network Bus CAN Wires Controller Area Network Wires License file needed to run the Diagnostic Tool Software . Controlled Config File by Hendrickson . Diagnostic tool Software used to communicate with the lift axle Software Electronic Control Unit...

  • Page 9: Parts List

    ***M5 Flange Hex Nut 53 ± 9 in lbs . NOTE: * Consult the vehicle manufacturer for applicable OPTIMAAX Air Controller Module . ** Item included in kit / assembly only, part not sold separately . Fasteners and torque value supplied by vehicle manufacturer . Contact vehicle manufacturer for additional service information .

  • Page 10: Air Controller Module

    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 . 7 . Connect the lift axle air plumbing to the OPTIMAAX air manifold per Air Manifold Diagram Section of this publication .

  • Page 11: Wiring Diagram

    THE ADDITION OF WEIGHT TO THE VEHICLE (APU - AUXILIARY POWER UNIT, CHAINS, ETC .) MAY CHANGE THE CORRECT OPTIMAAX DEPLOY THRESHOLD AND MAY REQUIRE REPLACEMENT OF THE ECU . FAILURE TO DO SO WILL OVERLOAD THE LIFT AXLE .

  • Page 12: Preventive Maintenance

    Preventive Maintenance AIR CONTROLLER MANIFOLD Appropriate inspection procedure is important to ensure the OPTIMAAX system is accurately mea- suring the system load . On an annual basis – the calibration of the pressure sensors, see Figure 8-1, in the air con- ■...

  • Page 13: Air Controller Manifold Diagram

    6 . A spring is used to retain a mesh filter on DRIVE and SUPPLY ports . These must be retained when PTC fittings are installed (not supplied by Hendrickson) . The mesh filter helps to prevent debris from entering the system .
  • Page 14 OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® OPTIMAAX AIR CONTROLLER MANIFOLD AIR AND ELECTRICAL PORTS TOP VIEW BOTTOM VIEW Air Port SUPPLY Air Port Electrical Port Electrical Port Electrical Port Air Port Electrical Port Electrical Port DRIVE...

  • Page 15: Section 10 Vehicle Air Plumbing Diagram

    OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® 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:...

  • Page 16: Section 11 System Operation

    (VPDM) in location F15, which houses the main fuse and relay center, see Figure 11-2 . d . Exhaust all pressure in lift axle air springs and vehicle air system . NOTE The OPTIMAAX air controller module weight thresholds to raise and deploy the lift axle are set by vehicle manufacturer . FIGURE 11-2...

  • Page 17: Section 12 Diagnostic Tool Software

    This Diagnostic Tool Software works with a laptop equipped with a 32-bit or 64-bit Windows  XP, ® Vista and Windows 7, 8 and 10 operating systems . Hendrickson provides access to software through NEXIQ, www .nexiq .com . THE DIAGNOSTIC TOOL SOFTWARE It is used to communicate with the lift axle controls .
  • Page 18 OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® FIGURE 12-2 Hendrickson OPTIMAAX Diagnostic Tool File Tools Help Select a COM Port from the pull down menu. There may be more than one com port available. Pick one, and click...
  • Page 19 OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® FIGURE 12-5 Hendrickson OPTIMAAX Diagnostic Tool File Tools Help Digital #2 Represents the parking brake signal FIGURE 12-6 Hendrickson OPTIMAAX Diagnostic Tool File Tools Help Click on History to view...
  • Page 20 CLOSE button on the START tab to terminate communication with the lift axle ECU, see Figure 12-7 . Exit the window, see Figure 12-7 . FIGURE 12-7 Hendrickson OPTIMAAX Diagnostic Tool File Tools Help STEP 3 Exit window STEP 2...

  • Page 21: Section 13 Troubleshooting Guide

    ® SECTION 13 Troubleshooting Guide To diagnose OPTIMAAX issues correctly, the following steps must first be performed: 1 . With vehicle disconnected from the trailer (bobtail) and ignition on, release parking brake . Observe if lift axle raises . 2 . Once lift axle is raised, wait 1 minute . Apply parking brake . Observe if lift axle deploys .
  • Page 22 OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® OPTIMAAX LIFT AXLE SYSTEM – ELECTRONIC COMPONENTS TROUBLESHOOTING GUIDE (Continued) SECONDARY PRIMARY CONDITION POSSIBLE CAUSE CORRECTION CONDITION Axle retracts Partially loaded trailer If axle scale is available, measure weight of drive...

  • Page 23: Fault Codes

    OPTIMAAX Lift Axle System Air Controller Module for Freightliner ® OPTIMAAX LIFT AXLE SYSTEM – ELECTRONIC COMPONENTS TROUBLESHOOTING GUIDE FAULT CODES SECONDARY PRIMARY CONDITION POSSIBLE CAUSE CORRECTION CONDITION OPTIMAAX warning Vehicle is overloaded Reduce vehicle load light is illuminated Fault detected . Mechanical...
  • Page 24 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. 17730-310 Rev A 07-18 © 2018 Hendrickson USA, L.L.C. All Rights Reserved Printed in United States of America...

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