Hendrickson TIREMAAX PRO Technical Procedure Download

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T51002 E

InstallatIon, servIce and troubleshootIng Procedures

PREPARING TRAIlER fOR SERVICE

NOTE: DO NOT

service a suspension or any

components that are under warranty without

first contacting Hendrickson Technical

Services. Refer to CONTACT HENDRICKSON for

details.

WARNING: To prevent serious eye injury, always

wear safety glasses when performing

trailer maintenance and service.

Figure 1:

Trailer preparation

Before beginning any work on a trailer suspension

system, the following steps help to ensure conditions

are safe. Refer to GENERAL SERVICE NOTES on

page 4.

Park

trailer on a level, debris-free surface.

Set

trailer parking brakes.

3. To prevent the trailer from moving,

chock

wheels

on axle not being raised.

Exhaust

air from the trailer suspension.

Release

trailer parking brakes.

6. If necessary, using a jack,

raise

trailer until

wheels clear the work surface.

Support

raised trailer with safety stands.

WARNING: Do not work under a trailer supported

only by jacks. Jacks can slip or fall

over, resulting in serious personal

injury.

Summary of Contents for TIREMAAX PRO

Page 1: ...nstallation instructions on suspensions with TIREMAAX DRESSED axles on page 23 through page 37 TIREMAAX UNDRESSED axles on page 13 through page 37 All other axles pre drilled on page 16 through page 37 All other axles not drilled on page 13 through page 37 CP T50013 08 11 ECN 20134 Copyright 2011 Printed in the USA REGULATOR FACTORY SET REFER TO T51002 OR CONTACT HENDRICKSON FOR ADJUSTMENT INFORMA...

Page 2: ...the System Operates 9 Tire Inflation 9 Tire Deflation TIREMAAX PRO only 9 Component Description 11 TIREMAAX Controllers 11 Hubcap 11 Axle Hoses and Fittings 12 Spindle Plug and Grommet 12 Tire Hoses 12 Indicator Lamp 12 Installation 13 Installation Materials and Supplies 13 Installation Introduction 13 Axle Preparation 13 Axle Component Installation 16 Axle Hose Installation 16 Additional Axles 17...

Page 3: ...on Intervals 44 Every Three Months 44 Every 12 months 44 In The Event Of A Leak 44 Checking for Air Leaks 44 Indicator Lamp Test 45 Manually Check Tire Pressure 46 Disable TIREMAAX TIS 47 Setting CP Target Pressure 48 Required Tools And Resources 48 Checking CP Delivery Pressure 48 Adjusting CP Delivery Pressure 49 Restore CP System To Normal Operation 49 Setting TIREMAAX PRO Target Pressure 50 Re...

Page 4: ... LINKS This documents includes links that can be applied when viewed electronically Links are identified by a dark grey line under the linked text GENERAL SERVICE NOTES IMPORTANT Special attention should be paid to the information included in EXPLANATION OF SIGNAL WORDS Before you begin Read understand and comply with All instructions and procedures All signal word CAUTION WARNING and DANGER state...

Page 5: ...elp avoid serious personal injury carefully follow the manufacturer s product instructions and guidelines and the following procedures Wear proper eye protection Wear clothing that protects your skin Work in a well ventilated area DO NOT use gasoline or solvents that contain gasoline Gasoline can explode Hot solution tanks or alkaline solutions must be used correctly Follow the manufacturer s reco...

Page 6: ... rear etc Symptoms Systems components or function effected by failure When does failure occur How often do they occur Etc What troubleshooting and or measurements have been performed 1 If the in service date is unknown or not available the vehicle date of manufacture can be substituted What service data literature do you have or need Digital photos of suspension and damaged areas Special applicati...

Page 7: ...eginning any work on a trailer suspension system the following steps help to ensure conditions are safe Refer to GENERAL SERVICE NOTES on page 4 1 Park trailer on a level debris free surface 2 Set trailer parking brakes 3 To prevent the trailer from moving chock wheels on axle not being raised 4 Exhaust air from the trailer suspension 5 Release trailer parking brakes 6 If necessary using a jack ra...

Page 8: ... prevent contamination of seals In axle filter prevents hub contamination and allows any wheel end air leaks to evacuate through the axle vent Seal and line leaks will not pressurize wheel ends No venting at wheel end helps prevent contamination from entering hubcap Integrated valves isolate tires from system when there is a problem e g damaged or flat tire The rotary union is incorporated in the ...

Page 9: ...mp to remain lit until the target pressure is reached The controller delivers constant pressure to lines and tires to maintain target pressure If there is a tire leak or leak in the lines the indicator lamp may or may not remain on Refer to TROUBLESHOOTING on page 37 If the indicator lamp Figure2 remains on for more than 10 minutes the system is attempting to inflate the tires but may not be able ...

Page 10: ... Power and Indicator lamp connection Integrated pressure control unit IPCU Petcock valve if included Emergency brake port PRO only SUPPLY port air in DELIVERY port air out Supply valve and filter Test port vent if included DELIVERY dump ports 2 Main power harness J560 interface Pressure relief module PRM on PRO only Indicator Lamp Figure2 TIREMAAX components Test port ...

Page 11: ... tank pressure for maintenance and other service functions Inlet screen reduces contamination from air supply Delivery port feeds regulated air pressure through air hoses and hubcaps to tires Petcock valve included on CP and older PRO models allows trailer mounted indicator lamp functionality to be tested See INDICATOR LAMP TEST on page 45 PRO only Emergency parking brake port when emergency or pa...

Page 12: ... hubcap shown AXLE HOSES AND FITTINGS Provide an air passage from the controller through the axle s to the hubcap Allows axle to remain non pressurized Refer to Figure9 through Figure39 for a complete description of air hoses and fittings SPINDLE PLUG AND GROMMET Provides air pressure vent breather hole for wheel end during normal use and in the event of increased pressure Restrains and positions ...

Page 13: ...and spindle plugs are already installed but undressed HUBCAP INSTALLATION on page 21 System hardware is already installed on a dressed axle TIRE HOSE INSTALLATION on page 23 Table3 Installation starting points 3 Components unique to TIREMAAX are available only from Hendrickson AXLE PREPARATION The first stage of TIREMAAX installation is axle preparation Starting with Figure5 this section defines p...

Page 14: ... of the axle on Hendrickson TRLAXLE Trailer Axles NOTE In most cases it will be necessary to remove the slack adjuster and camshaft to gain access to the approved drilling area on INTRAAX and VANTRAAX suspensions Refer to Hendrickson publication L496 Wheel End Maintenance Procedures available at www hendrickson intl com literature for complete slack adjuster and camshaft removal instructions 10 Re...

Page 15: ...dle end Figure7 Hendrickson TRLAXLE drilling details NOTICE Before drilling make sure holes will not interfere with suspension mounting method If hole will interfere contact Hendrickson Technical Services using CONTACT HENDRICKSON on page 6 NOTE Figure7 drilling details are for Hendrickson TRLAXLE If other than TRLAXLE CONTACT HENDRICKSON Figure8 Routing axle hose Top View Route braided hose into ...

Page 16: ...losest to the spindle end Figure8 On Hendrickson TRLAXLE Trailer Axles route the small end of the metal braided hose into the hole closest to the spindle 2 Making sure hose heads toward the spindle end continue feeding metal braided hose into the axle tube until small end of the hose exits spindle end 3 Thread the large adapter end of axle hose assembly into axle 4 Tighten fitting to 20 ft lbs 27 ...

Page 17: ...t orient the axle connector fitting to obtain the best slack adjuster air line clearance It is the OEMs responsibility to route air lines and orient axle connector fittings so as to eliminate interference between slack adjusters and air lines Lines should be protected against chaffing when passing through or by metal edges Figure11 Suggested control line installation details for Top Mount Narrow B...

Page 18: ... High Flow Axle Vent is installed in the previously drilled hole as shown in Figure15 Refer to Axle Preparation on page 13 for drilling details NOTICE To prevent contamination of the axle ensure High Flow Axle Vent is securely fastened and vent tube points down WARNING Failure to properly install axle vent may result in wheel end pressurization and or water ingestion This could cause wheel end fai...

Page 19: ...o point downward after torquing 4 Remove and discard paint plug if present ITEM NAME SPINDLE TYPE A DIMENSION PART NUMBER 1 Plug Driver HN 1 75 inches S 28146 1 HP1 2 75 inches S 28146 3 2 Plug Driver Handle N A N A S 27399 1 Before March 28 2003 Hendrickson manufactured HP spindles with both 2 50 and 2 75 inner bore diameters After this date the HP spindle bore was standardized at 2 75 Figure17 S...

Page 20: ...With spindle plug breather hole oriented toward the pivot bushing Figure17 place plug assembly against the spindle end 4 With axle hose brass fitting centered in the plug driver press plug into spindle end until driver bottoms on end of spindle Repeat Step 1 through Step 4 for each wheel end NOTE The recommended plug driver refer to the table in Figure17 regulates the correct installation depth as...

Page 21: ... thread rotary union onto axle hose fitting DO NOT rotate axle hose fitting 4 Similarly to Figure19 applying an inch pound torque wrench on the 7 16 inch flats on rotary union shaft and 3 8 inch wrench on the flats of the axle hose fitting tighten connection to 50 5 in lbs 5 7 0 6 N m NOTICE For clocking of tire hose positioning review TIRE HOSE INSTALLATION on page 23 before proceeding 5 Place tw...

Page 22: ... NOTE When the wheel is installed verify Tire hose is not stretched so tightly a strain is introduced at either the valve stem or hubcap Make sure the tire hose is not so loose it contacts the wheel Check to ensure no portion of the tire hose extends out past the wheel Figure22 Properly clocking hubcap and wheels to prevent tire hose damage during operation 90 ...

Page 23: ...e stem connection finger tight Figure23 5 Using a 7 16 inch wrench tighten the tire hose valve stem connection an additional one half turn Figure23 Do not overtighten this connection NOTE If using a torque wrench Torque to 28 2 0 in lbs 3 0 0 N m 6 Ensure hose connections are tight enough that when moving the hose back and forth it does not cause the connection to move IMPORTANT Hold tire hose wit...

Page 24: ...ria is recommended when locating and mounting the controller assembly Protect the controller and air lines from flying debris Provide a secure and stable mounting surface Allow access for maintenance Provide easy access to a reservoir emergency supply line and delivery lines Mount with door hinge at top with room to open door and if included petcock pointing down If required use the hole pattern s...

Page 25: ... holes for mounting the TIREMAAX controller directly to crossmembers Figure30 and Figure31 Holes are also provided for various other brackets and options NOTE Four holes are provided for mounting controller to rear crossmember Figure30 Mounting to rear crossmember of ULTRAA K slider recommended NOTE Holes are also provided for mounting an optional OE bracket to the front crossmember Figure31 Mount...

Page 26: ...commendations are also included Available diagrams include For CP installation refer to Figure34 to Figure36 For PRO installation refer to Figure37 to Figure39 For ADDITIONAL AXLES on page 17 refer to Figure10 to Figure14 The following plumbing criteria must be followed during TIREMAAX installation Use a wrench to hold axle hose fitting to prevent twisting of air line inside the axle Proper TIREMA...

Page 27: ...ting Run tee 1 8 inch NPT male 3 8 inch NTA 3 8 inch NTA gauge is optional I Tee assembly 1 4 inch NPT union tee two 1 4 inch NTA fittings and one 3 8 inch NTA fitting four total J Pressure protection valve PPV 1 Required 70 PSI minimum closing pressure existing suspension valve can be used K PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA 1 May be provided with Height Control ...

Page 28: ... 4 inch NTA 1 4 inch NTA three total gauge is optional G Air line 3 8 inch OD nylon air brake tubing H Pressure protection valve PPV 1 Required 70 PSI minimum closing pressure existing suspension valve can be used I PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA 1 May be provided with Height Control Valve HCV or Dock Stabilizing Technology DST kit Figure35 Typical TIREMAAX CP ...

Page 29: ...inch NTA gauge is optional I Junction manifold1 3 8 inch NTA inlet 1 4 inch NTA outlets J Pressure protection valve PPV 2 Required 70 PSI minimum closing pressure existing suspension valve can be used K PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA 1 These parts are available from Hendrickson Refer to LITERATURE on page 6 to get part numbers 2 May be provided with Height Cont...

Page 30: ...h NTA gauge is optional I Tee assembly 1 4 inch NPT union tee two 1 4 inch NTA fittings and one 3 8 inch NTA fitting four total J Pressure protection valve PPV 1 Required 70 PSI minimum closing pressure existing suspension valve can be used K PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA L Emergency supply IN fitting 1 4 inch NPT male to 3 8 inch NTA 1 May be provided with He...

Page 31: ... NTA 1 4 inch NTA three total gauge is optional H Pressure protection valve PPV 1 Required 70 PSI minimum closing pressure existing suspension valve can be used I PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA J Emergency supply IN fitting 1 4 inch NPT male to 3 8 inch NTA 1 May be provided with Height Control Valve HCV or Dock Stabilizing Technology DST kit Figure38 Typical T...

Page 32: ...NTA outlets I Pressure protection valve PPV 2 Required 70 PSI minimum closing pressure existing suspension valve can be used J PPV OUT fitting Run tee 1 4 inch NPT male 3 8 inch NTA 3 8 inch NTA K Emergency supply IN fitting 1 4 inch NPT male to 3 8 inch NTA 1 These parts are available from Hendrickson Refer to LITERATURE on page 6 to get part numbers 2 May be provided with Height Control Valve HC...

Page 33: ... optional wire harnesses available from Hendrickson Detailed information and criteria are also provided Figure40 shows a typical wiring schematic for the TIREMAAX systems Figure41 shows various connections based on the options selected for the installation Figure40 Typical wiring schematic for indicator lamp NOTE TIREMAAX PRO controller shown CP controller connector is on the right side B C A From...

Page 34: ... circuit 4 Connect 3 pin Delphi Weather Pack male connector into to the controller assembly as shown in Figure41 on page 33 5 Weatherproof all terminals and connectors as needed Corrosion prevention compound must be used on all connectors Refer to TMC RP 113 114 120 and 154 for recommended wiring practices 6 Secure harness and wires as needed Refer to ADDING RESTRAINT TO WIRING 7 Proceed to TRAILE...

Page 35: ...ator lamp wires according to information provided in Figure41 on page 33 and wire harness installation instructions on page 34 SYSTEM INTEGRITY CHECK After the installation is complete but before the trailer is put into service all air system connections must be tested To accomplish this A Complete the procedure CHECKING FOR AIR LEAKS on page 44 B Perform the INDICATOR LAMP TEST on page 45 For PRO...

Page 36: ...43 Trailer decal locations TIREMAAX TIRE INFLATION SYSTEM www hendrickson intl com T50007 Rev A 11 14 ECN 23615 Printed in the United States of America 2014 Hendrickson USA L L C U S Rights Hendrickson Intl Corp Rights Outside U S All Rights Reserved Trailer Commercial Vehicle Systems 2070 Industrial Place SE Canton OH 44707 2641 USA 866 RIDEAIR 743 3247 330 489 0045 FAX 800 696 4416 Trailer Comme...

Page 37: ... leaking at all TIREMAAX components If not found proceed to B If found and the fix is not obvious proceed to Step 2 B Check tires and components for leaks using a soapy water solution and check each tire for a low pressure condition Refer to IN THE EVENT OF A LEAK on page 44 Proceed to Step 2 if needed 2 From TROUBLESHOOTING MATRIX on page 38 select the effect letter that best matches the symptoms...

Page 38: ...ged No delivery pressure Low delivery pressure Controller cover will not close Probable Causes 4 A B C D E F G H I J K L M N O P Q System is functioning normally 1 4 4 Leakage Slow leak 2 4 4 4 4 4 4 4 Medium leak 3 4 4 4 4 4 4 4 4 4 Severe leak 4 4 4 4 4 4 4 4 Leak at hubcap assembly 5 4 4 4 4 Axle hose leak 6 4 4 4 Tire hose leak 7 4 4 Tire or rim leak 8 4 Manifold leak if included 9 4 4 4 Axle ...

Page 39: ...valves automatically close when necessary F Tires low at any one wheel end All other wheel ends appear to have normal inflation and tire pressure G Tires low on one axle Tires are low at both wheel ends of a common axle H Tires not inflating to target Tires are low and no indicating of inflation from TIREMAAX Refer to effect E I One dual tire low Only one tire is affected for the wheel end of a du...

Page 40: ...imum air flow In this case the source of the leak should be audible and obvious I Check for system damage and obvious leaks II If necessary perform SYSTEM INTEGRITY CHECK on page 35 III Repair as needed 5 Leak at hubcap assembly Rotary union or other assembled components in hubcap assembly may have worn or failed resulting in a leak or blockage Leaking air pressure in the wheel end and axle is ven...

Page 41: ... to filter larger debris from entering and contaminating the air within the system However should passable bits of debris collect at any point within components of the system a blockage can occur Regular maintenance of the compressor and air tank can help to avoid this problem I Check and clean the screen filter at the supply valve Replace valve as needed II If the effect of a possible blockage ca...

Page 42: ...n The test port vent is included with current TIREMAAX PRO controllers It can be threaded to the test port in the TEST or STORE position see INDICATOR LAMP TEST on page 45 If left in the TEST position 1 Air may leak out the test port 2 The controller cover will not properly close Unthread test port vent from the test port flip and reinstall in the STORE position Ensure cover completely closes and ...

Page 43: ...f rubber components and must be avoided 2 The system identifies leaks and reports them by illuminating the trailer mounted indicator lamp The operator is informed whenever a tire is low enough to require service or there is a leak in the system Wheel valves isolate the leaking or damaged wheel from the system Probable cause 2 3 and 4 help identify the severity of the leak in general and apply to a...

Page 44: ...lamp see INDICATOR LAMP TEST on page 45 2 Manually check all tires for a low pressure condition by removing the tire hoses at the hubcap using MANUALLY CHECK TIRE PRESSURE on page 46 3 Inspect all tire hoses to ensure that they are secure EVERY 12 MONTHS In addition to the above three month check perform the following 1 Inspect all system connections for leaks Apply soapy water to all air fitting ...

Page 45: ...ply soapy water to all air fitting connections Bubbles in the soapy water will provide a visual indication of an air leak NOTE Simply spraying the connections to look for leaks is acceptable Using a commercially available leak detector solution or soapy water to verify airtight connections is best and recommended 6 At axle vent listen for air flow through the vent tube and apply leak detection flu...

Page 46: ... the circuit should be closed If circuit is open replace controller ii Apply 12 VDC power directly to the lamp If indicator lamp is not on replace the indicator iii If indicator lamp is still not on check wiring 4 Test complete A If included Unthread test port vent reinstall in the STORE position and close the controller cover B If included Completely close petcock at controller MANUALLY CHECK TIR...

Page 47: ... from tire DISABLE TIREMAAX TIS This procedure may be required in case of a system leak or failure 1 Set trailer emergency brake Figure49 Supply valve closed 2 Located on the TIREMAAX controller turn Supply valve to closed position Figure49 3 At each tire A Detach tire hose at the hubcap B Check tire for correct inflate pressure Refer to MANUALLY CHECK TIRE PRESSURE C Completely remove tire hose s...

Page 48: ... may also be used 9 2 10 1 bar psi 0 100xkPa 11 0 20 140 16 0 10 0 6 80 8 7 60 5 3 4 40 120 Figure51 CP target gauge VS 32344 NOTE The TIREMAAX PRO target gauge Figure53 on page 50 can not be used in place of the CP target gauge Fittings are not compatible CHECKING CP DELIVERY PRESSURE Follow this procedure to check pressure in the delivery line Figure50 for TIREMAAX CP systems 1 Chock wheels or o...

Page 49: ... Always approach the target pressure setting from an increasing pressure direction B If delivery pressure is too high i Decrease it by rotating the regulator knob counterclockwise as viewed from the end of the knob ii Lower the pressure setting to at least 5 psi below the desired cold target pressure setting iii Turn knob clockwise again to the desired cold target pressure setting 3 Close controll...

Page 50: ...rforming these procedures Refer to CHECKING FOR AIR LEAKS on page 44 WARNING Emergency air supply must be available at the Emergency supply port on the controller to enable TIREMAAX PRO operation Supplying air at the emergency gladhand will also release trailer brakes REQUIRED TOOLS AND RESOURCES The following tools and resources are required to adjust TIREMAAX PRO controller settings Clean dry sh...

Page 51: ...valve B Open the shop supply valve You should hear air exiting the valve C Close the shop supply valve Air should stop exiting after 45 to 60 seconds D Read and record the target gauge pressure This is the current Deflation Pressure 7 Compare measured INFLATION and DEFLATION pressure readings to desired settings NOTE Delivery deflation pressure should be 10 psi higher than the specified cold targe...

Page 52: ...pressure 1 Set the emergency brakes 2 Close controller supply valve at the controller Figure52 on page 50 3 Connect clean dry shop air supply to target gauge using the 1 4 inch quick connect Figure53 on page 50 An air supply at least 15 psi above cold inflation pressure is required 4 Open gauge shop supply valve The flowing air should create an audible sound that will stop when current deflation p...

Page 53: ...tor C Indicator lamp connector D Controller assembly connector 2 Refer to ADDING RESTRAINT TO WIRING on page 34 to weatherproof secure and restrain harness and wiring as needed CONTROLLER ASSEMBLY REPLACEMENT This procedure replaces the controller assembly as one complete unit For controller connections refer to For CP Figure50 on page 48 For PRO Figure52 on page 50 REMOVAL 1 Exhaust air from trai...

Page 54: ... as needed making sure the wheel is properly oriented as recorded in Step 3 Figure54 Reattaching tire hoses to tire valve stem 6 Attach tire hose s to tire valve stem s and tighten finger tight Figure54 NOTE Tire hoses must be connected directly to the tire valve stems and hubcap port Do not use valve stem extenders 7 Using a 7 16 inch wrench tighten tire hose valve stem connection an additional o...

Page 55: ...sure Control Unit The IPCU is set with the target tire pressure and directs the system to supply air to the tires when needed A significant amount of system air flow causes the trailer mounted indicator lamp to illuminate OE or OEM Original Equipment Manufacturer PRM Pressure Relief Module A unit in a TIREMAAX PRO controller that allows tire deflation Rotary union Rotary air seal assembly that all...

Page 56: ...86 88 90 92 94 96 98 100 120 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 110 71 73 75 77 79 82 84 86 88 90 92 94 96 98 100 102 104 100 74 77 79 81 83 85 87 89 91 94 96 98 100 102 104 106 109 80 76 78 81 83 85 87 89 91 94 96 98 100 102 104 106 109 111 70 78 80 82 85 87 89 91 93 96 98 100 102 104 107 109 111 113 60 80 82 84 86 89 91 93 95 98 100 102 105 107 109 111 114 116 50 100 103 105 10...

Page 57: ... 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 120 110 100 90 80 70 60 50 40 30 20 10 0 TIRE PRESSURE VS TEMPERATURE Temperature ºF Pressure PSIG Drops to 89 psig at 20º F Set 100 psig at 70º F Figure56 Typical tire maintenance system performance at 100 psig ...

Page 58: ...58 T51002 E Installation Service and Troubleshooting Procedures NOTES ...

Page 59: ...59 T51002 E Installation Service and Troubleshooting Procedures ...

Page 60: ...Parque Industrial El Marqués Pob El Colorado Municipio El Marqués Querétaro México C P 76246 52 442 296 3600 Fax 52 442 296 3601 Call your trailer dealer or Hendrickson at 866 RIDEAIR 743 3247 for additional information Printed in United States of America Information contained in this literature was accurate at the time of publication Product changes may have been made after the copyright date tha...

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