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PRIMAAX

EX / PRIMAAX

Rear

Air Suspension for International
Truck Vehicles

SUBJECT:

Service Instructions

LIT NO:

17730-283

DATE:

June 2012

REVISION:

TABLE OF CONTENTS

Section 1

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . 2

Section 2

Product Description

. . . . . . . . . . . . . . . . . . 2

Section 3

Important Safety Notice

. . . . . . . . . . . . . . . 5

Section 4

Parts Lists

. . . . . . . . . . . . . . . . . . . . . . . . . 10

Section 5

Special Tools

. . . . . . . . . . . . . . . . . . . . . . . 21

Section 6

Preventive Maintenance

. . . . . . . . . . . . . 24

Hendrickson Recommended Preventive
Maintenance Intervals . . . . . . . . . . . . . . . . . 24

Component Inspection . . . . . . . . . . . . . . . . . 26

U-bolt Locknuts . . . . . . . . . . . . . . . . . . . . . . . 28

Pivot Bushing and D-Pin Bushing Inspection . 29

Longitudinal and Transverse Torque Rods . . . 31

Shock Absorber Inspection . . . . . . . . . . . . . . 32

Air Fitting Inspection . . . . . . . . . . . . . . . . . . . 33

Section 7

Alignment & Adjustments

. . . . . . . . . . . . 34

Ride Height . . . . . . . . . . . . . . . . . . . . . . . . . 34

Lateral Alignment . . . . . . . . . . . . . . . . . . . . 34

Drive Axle Alignment Inspection Procedure . . 34

Alignment Adjustment Instructions . . . . . . . . 36

Axle Pinion Angle . . . . . . . . . . . . . . . . . . . . . 38

Axle Pinion Angle Adjustment . . . . . . . . . . . . 38

Section 8

Component Replacement

. . . . . . . . . . . . 39

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Height Control Valve . . . . . . . . . . . . . . . . . . . 39

Air Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Air Spring / Upper Air Spring Bracket . . . . . . . 41

Shock Absorber . . . . . . . . . . . . . . . . . . . . . . 42

Transverse Torque Rod . . . . . . . . . . . . . . . . . 44

Longitudinal Torque Rod . . . . . . . . . . . . . . . . 44

Torque Rod Bushing . . . . . . . . . . . . . . . . . . . 46

Support Beam Assembly and Cross Tube . . . 47

U-beam Assembly . . . . . . . . . . . . . . . . . . . . 48

D-pin Bushing . . . . . . . . . . . . . . . . . . . . . . . 51

QUIK-ALIGN Pivot Bushing . . . . . . . . . . . . . . . 56

Top Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Bottom Cap and axle spacer (If equipped) . . 59

S-Cam Support Bracket (If equipped) . . . . . . 62

Axle Stops . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Frame Hanger . . . . . . . . . . . . . . . . . . . . . . . 63

Section 9

Torque Specifi cations

. . . . . . . . . . . . . . . 66

Section 10

Troubleshooting Guide

. . . . . . . . . . . . . . 74

Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • [email protected]

Содержание Primaax EX 232

Страница 1: ...rickson replacement part specialists at Pro Gear and Transmission Pro Gear Transmission has same day shipping and 1000 s of products in stock and ready to ship internationally for your next project For parts or service contact the Hendrickson specialists at Pro Gear Transmission Inc 1 877 776 4600 407 872 1901 parts eprogear com ffiHENDRICKSON 4 e m UR 1 msClhUs Pro Gear and Transmission 906 W Gor...

Страница 2: ...ght 34 Lateral Alignment 34 Drive Axle Alignment Inspection Procedure 34 Alignment Adjustment Instructions 36 Axle Pinion Angle 38 Axle Pinion Angle Adjustment 38 Section 8 Component Replacement 39 Fasteners 39 Height Control Valve 39 Air Spring 39 Air Spring Upper Air Spring Bracket 41 Shock Absorber 42 Transverse Torque Rod 44 Longitudinal Torque Rod 44 Torque Rod Bushing 46 Support Beam Assembl...

Страница 3: ...contains parts lists safety information product specifications features proper main tenance service repair and rebuild instructions for PRIMAAX EX PRIMAAX suspension systems 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...

Страница 4: ...n geometry Optimized suspension geometry contributes to more than twice the roll stability of competitive air suspensions helps improve handling and roll stiffness for expanded applications and significantly controls suspension induced driveline vibration Large volume air springs Reduce noise vibration and harshness to cab chassis and body equipment for reduced total vehicle maintenance Also reduc...

Страница 5: ... and all hardware Published weight is based on a standard PRIMAAX EX suspension compatible with drum brakes Other configurations may vary 2 Contact Hendrickson or vehicle manufacturer for applications that may exceed GVW GCW approval ratings 3 Site travel rating operators using vehicles equipped with liftable pusher or tag axles must not exceed published ratings Ratings are limited to no more than...

Страница 6: ...roper service meth ods 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 hazards 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 defi...

Страница 7: ...IN PERSONAL INJURY OR PROPERTY DAMAGE LOAD CAPACITY ADHERETOTHE PUBLISHED CAPACITY RATINGS FORTHE SUSPENSION ADD ON AXLE ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES SUCH AS LIFTABLE AXLES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED AND APPROVED CAPACITIES WHICH CAN RESULT IN COMPONENT DAMAGE AND LOSS OF VEHICLE CONTROL POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE MODIFYING COMPONEN...

Страница 8: ...EING REMOVED 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 AIR SPRING PRESSURE RETENTION SOME VEHICLE APPLICATIONS SUCH AS VEHICLES EQUIPPED WITH OUTRIGGERS RETAIN SOME AIR PRESSURE IN THE AIR SPRINGS AT ALL TIMES PRIOR ...

Страница 9: ...IR OR SERVICE WORK SITE DUMPING BEFORE THE TRUCK TRAILER BODY BOOM AND OR ATTACHMENT IS LIFTED IT IS MANDATORY TO COMPLETELY EXHAUST THE AIR FROM THE REAR SUSPENSION SYSTEM AND AUXILIARY AXLE IF EQUIPPED TO HELP PROVIDE STABILITY FAILURE TO DO SO CAN RESULT IN LOSS OF VEHICLE CONTROL ROLL OVER OR VEHICLE INSTABILITY POSSIBLY CAUSING SEVERE PERSONAL INJURY PROPERTY DAMAGE OR DEATH FIRST RAISE ANY A...

Страница 10: ...N 3 WORK IN A WELL VENTILATED AREA 4 DO NOT USE GASOLINE OR SOLVENTSTHAT CONTAIN GASOLINE GASOLINE CAN EXPLODE 5 HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY FOLLOW THE MANUFACTURER S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY TO HELP PREVENT PERSONAL ACCIDENT OR INJURY DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR POLISHED PARTS DOING S...

Страница 11: ...RE 4 2 PRIMAAX ISupport Beam with Detachable End Cap Beam Support DETACHABLEEnd Cop PRIMAAX EX 232 462 692 PRIMAAX EX 232T 462T 692T PRIMAAX EX 262S Upper Air Spring Bracket Air Spring Flared Piston FIGURE 4 3 9 Ride Height Frame Hanger AND Axle Spac rboll n Axle Spacer 1 I Bottom Cap I Support Beam Upper Air Spring Bracket Air Spring Flared Piston 0 0 Oi 1 ii dhl 1O Ride Height AND PRIMMX EX Fram...

Страница 12: ...ket Service Kit PRIMAAX EX SERIES U beam Assembly Enhancement Aftermarket Service Kit No 69565 001 Axle Set PART NO DESCRIPTION QTY COMMENTS 69351 000 Sikaflex 221 Polyurethane Sealant 300 ml Tube 1 In the event any service to the suspension requiring disassembly of a U beam assembly equipped with integrated end caps the Loctite 277 tamper resistant caps and Sikaflex 221 polyurethane sealant must ...

Страница 13: ...3 PRIMAAX EX 232 462 692 for International Truck Vehicles 9 10 Ride Height 34 1 25 ____ ______ 26 15 i 14 I i 21 22 23 I Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 14: ...Length 5 0 b 21867 026 Length 5 5 c 21867 043 Length 4 75 18 22962 001 Flat Washer 16 19 30191 000 16 UNF Locknut 8 60961 664 Single Air Spring Service Kit Includes Key Nos 20 23 20 67234 002 Air Spring Assembly Includes Upper Frame 4 Bracket and Fasteners 21 60911 002 Lower Air Spring Mounting Bracket 4 22 22962 014 Flat Washer 8 23 17700 010 13 UNC Locknut 8 24 Longitudinal Torque Rod Assembly 1...

Страница 15: ...AX EX 232T 462T 692T for International Truck Vehicles 13 Ride Height 3 5 6 80 i 17 I i _ 18 _ 16 18 19 14 M 26 22 23 38 H l J 38 Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 16: ...s Key Nos 20 26 20 65031 001 Upper Air Spring Bracket Assembly 4 21 67923 002 Air Spring Assembly Includes Upper Frame 4 Bracket and Fasteners 22 22962 014 Flat Washer 12 23 17700 010 13 UNC Locknut 12 24 22962 001 Flat Washer 4 25 17700 031 16 UNF Locknut 4 26 60911 002 Lower Air Spring Mounting Bracket 4 27 Longitudinal Torque Rod Assembly Includes 2 Bushings Measure length in mm 2 a 62043 430N ...

Страница 17: ...ational Truck Vehicles 9 Ride Height Location of S cam Bracket Part No l 27 0 23 24 I 25 i _ i i i 14 i I i 1 _ 15 QO 17 18 H l J 29 0 29 21 30 31 47 Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 18: ...t and Fasteners 20 60911 002 Lower Air Spring Mounting Bracket 2 21 22962 014 Flat Washer 4 22 17700 010 13 UNC Locknut 4 23 Longitudinal Torque Rod Assembly See table on page 11 49176 032 Longitudinal Torque Rod Fastener Service Kit Axle Set Includes Key Nos 24 26 24 32043 016 5 8 11 UNF 8 0 Hex Bolt 8 25 22962 004 5 8 Flat Washer 16 26 47764 000 5 8 11 UNC Locknut 8 27 49689 000 Shim As Required...

Страница 19: ...s Lists 18 17730 283 PRIMAAX 230 460 690 for International Truck Vehicles 9 Ride Height H l J 49 47 6 Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 20: ...orque Rod Assembly 1 See table on page 11 49176 026 LongitudinalTorque Rod Fastener Service Kit One Torque Rod Includes Key Nos 29 34 29 32043 016 5 8 11 UNC 2B 8 0 Bolt 16 30 22962 004 5 8 Flat Washer 32 31 47764 000 5 8 11 UNC 2A Locknut 16 58821 012 Longitudinal Torque Rod Rear Bolt Service Kit One Torque Rod Includes Key Nos 32 34 32 30418 009 7 8 14 UNF 2A 5 5 Hex Bolt 4 33 22962 034 7 8 H Co...

Страница 21: ...X QUIK ALIGN Concentric Collar 2 2 PAX QUICK ALIGN Eccentric Collar 2 3 1 12 UNF Bolt 8 0 2 4 1 Hardened Washer 4 5 1 12 UNF Nylocknut 2 PRIMAAX 230 460 690 9 10 13 Ride Height KEY NO KIT NO DESCRIPTION QTY 58821 026 Top Pad Bolt Severe Service Kit Axle Set Includes Key Nos 1 3 Does not include Top Pad 1 M24 x 3 0 6G H coat Hex Bolt 2 2 M24 Hardened Washer 4 3 M24 x 3 0 6H Locknuts 2 NOTE Item inc...

Страница 22: ...ls are made from cold rolled steel or equivalent Drawings are for reference only Hendrickson does not supply these tools H l J QUIK ALIGN TOOLS Pivot Bushing Installer b 0 M L__ D PIN TOOLS Installer 0 1 85 Pivot Bushing Remover J 0 II M j 0 0 L Remover 0 0 ari 0 0 co Pivot Bushing Receiver Receiver Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear...

Страница 23: ...tified by the part number 67428 XXX or the suffix N after any part number i e 62000 615N QUIK ALIGN SOCKETTOOL Hendrickson PRIMAAX EX PRIMAAX QUIK ALIGN SocketTool is available from the OwatonnaTool Corporation Owatonna Part 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 discretio...

Страница 24: ...ove the tires to gain access to the detachable end cap bolt NOTE Due to some vehicle configurations and or tire sizes wheel removal may be required Use the Quick Wrench tool with Hendrickson PRIMAAX suspensions detachable end cap see Figure 5 2 and on the longitudinal torque rod to top pad configuration illustrated in Figure 5 3 Any questions regarding the Quick Wrench tooling applications contact...

Страница 25: ...e bracket Longitudinal Clamp group Shock absorbers U beam assembly Top pad Suspension wear and damage Cross tube U bolt locknuts Tire wear Support beam End cap if equipped Signifies performance critical components HENDRICKSON RECOMMENDED PREVENTIVE MAINTENANCE INTERVALS PRE DELIVERY INSPECTION PRIMAAX EX 1 Visually inspect the suspension for proper assembly 2 Verify the lateral alignment of the dr...

Страница 26: ...all fasteners for proper torque with special attention to the following suspension connections QUIK ALIGN fasteners see Figure 6 2 Torque rod to top pad fasteners see Figure 6 2 Clamp group fasteners U bolts see Figure 6 3 FIGURE 6 3 H l J Enhanced U beam Assembly with Integrated End Cap NO RE TORQUE REQUIRED Tamper Resistant Cap attached to integrated end cap bolts with SIKAFLEX 221 sealant appli...

Страница 27: ...ns COMPONENT INSPECTION IMPORTANT NOTE Replace all worn or damaged parts Air spring Visually inspect the outer surface of the air spring for chafing uneven wear cracks or any signs of component damage Ensure that the upper bead plate is tight against the underside of the frame Check for any lateral slippage at the lower air spring bracket An 1 8 of slippage in either direction is acceptable Verify...

Страница 28: ...r wear patterns that may indicate suspension dam age or misalignment Top pad Longitudinal torque rod connection Visually inspect the connection for signs of movement or damage Use a lever check to help assess movement in this joint see Longitudinal andTransverseTorque Rods in this section for proper inspection Verify theTop Pad Longitudinal Torque Rod connections have the proper torque values main...

Страница 29: ... PRIMAAX EX PRIMAAX suspensions are 16 UNF Grade C locknuts and 16 UNF Grade 8 U bolts which are phosphate and oil coated IT IS IMPORTANT THAT THE U BOLT CLAMP GROUP CONNECTION BE PROPERLY ALIGNED AND HAVE THE PROPER TORQUE VALUES MAINTAINED METAL SURFACES CAN WORK AND WEAR AGAINST OTHER RELATED CLAMP GROUP COMPONENTS IF NOT PROPERLY ALIGNED OR PROPERLY TIGHTENED TO MAINTAIN THE PROPER CLAMP FORCE...

Страница 30: ...bushing is not centered in the end hub it is an indication that the pivot bushing could be worn and a pivot bushing physical inspection is required If the pivot bushing shows signs of torn separated or disconnected rubber see Figures 6 7 and 6 8 this could be a result of axle misalignment If this condition is evident a pivot bushing physical inspection is required If the outer rubber flange s is m...

Страница 31: ...r damaged 6 Check the suspension alignment and adjust if necessary Refer to Alignment Adjustments Section of this publication D PIN BUSHING VISUAL INSPECTION It is not necessary to disassemble the D Pin connection to perform a D Pin visual inspection The D Pin bushing is designed with a layer of rubber in the bushing it is acceptable to see a bead of rubber protruding from the bushing see Figure 6...

Страница 32: ...trol acceleration and brake forces refer to the Pinion AngleTable in the Parts Lists Section of this publication Transverse rod length is also determined by the vehicle manufacturer to center the axles under the frame If the lateral alignment of the axles is incorrect it may be necessary to shim the transverse torque rod at the straddle mount end Shims can be installed between the transverse torqu...

Страница 33: ...on It is not neces sary to replace shock absorbers in pairs if one shock absorber requires replacement HEATTEST 1 Drive the vehicle at moderate speeds on rough road for minimum of fifteen minutes DO NOT GRAB THE SHOCK AS IT COULD POSSIBLY CAUSE PERSONAL INJURY 2 Lightly touch the shock body carefully below the dust cover see Figure 6 16 3 Measure the shock absorber temperature using an Infrared Te...

Страница 34: ... Replace as necessary NOTE PRIMAAX EX PRIMAAX suspensions are equipped with a premium seal on the shock however this seal will allow for misting to appear on the shock body misting is not a leak and is considered acceptable If the shock is damaged install new shock absorber and replace as detailed in the Component Replacement Section of this publication AIR FITTING INSPECTION 1 If an air leak is s...

Страница 35: ... the same axle Record the measurement 10 Subtract the two measurements to get a difference between the two If the difference is greater than 1 8 3 mm it will be necessary to correct the lateral alignment Adding or removing shims that are located between the transverse torque rod and frame rail accom plishes this A general rule of thumb is to use a shim with a thickness that is half of the differen...

Страница 36: ...lignment of this axle by following the proper alignment instructions for PRIMAAX EX PRIMAAX suspension model as deter mined 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...

Страница 37: ... WITH SPECIAL COATING H COAT TO SUSTAIN PROPER CLAMP FORCE FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE OR PERSONAL INJURY AND VOID WARRANTY ENSURE THAT THE QUIK ALIGN FASTENER S TORQUE VALUES ARE SUSTAINED AS RECOMMENDED INTHETORQUE SPECIFICATIONS SECTION OFTHIS PUBLICATION FAILURETO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE 1 Su...

Страница 38: ...oper ride height adjustment NOTE When adjusting the alignment of an axle the fasteners connecting the longitudinal torque rod to the frame hanger above the QUIK ALIGN collar being adjusted must be loose at the frame hanger This will allow the longitudinal torque rod to move freely with the axle while the alignment is adjusted Failure to do so will result in bushing preload in all rubber connection...

Страница 39: ...side may differ due to axle alignment 1 Loosen the fasteners connecting the longitudinal torque rods to the frame hangers 2 Install or remove shims as required in equal amounts to both sides of the axle to achieve the proper pinion angle see Figure 7 6 To increase the pinion angle install shims To decrease the pinion angle remove shims SERVICE HINT A general rule of thumb is 1 8 change in the shim...

Страница 40: ...tions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system 5 Lower the height control valve arm s to exhaust the air in the air springs and deflate the rear suspension SOME VEHICLE APPLICATIONS SUCH AS VEHICLES EQUIPPED WITH OUTRIGGERS RETAIN SOME AIR PRESSURE IN THE AIR SPRINGS AT ALL TIMES PRIOR TO PERFORMING ANY MAINTENANCE SERVI...

Страница 41: ...e engaging the mounting air spring studs see Figure 8 1 5 Using HAND TOOLS install the lower mounting fasteners and tighten to 20 30 foot pounds torque 6 Reconnect the air line to the air spring 7 See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system 8 Inflate the suspension slowly and verify that t...

Страница 42: ...he air spring is being removed for an alternate repair it will be necessary to lubricate the lower mounting fasteners with penetrating oil This will help prevent the air spring mounting studs from breaking during the removal process 8 Remove and discard the lower mounting fasteners from the air springs using HANDTOOLS only 9 Remove the lower air spring mounting bracket from the cross tube 10 Remov...

Страница 43: ...ve linkage s to the height control valve arm s to inflate the suspension 13 Remove the frame supports 14 Verify the ride height is within specification refer to vehicle manufacturer for proper ride height adjustment 15 Remove the wheel chocks SHOCK ABSORBER THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SUSPENSION ANYTIME THE AXLE ON A PRIMAAX EX PRIMAAX SUSPENSION IS SUSPENDED IT IS MAN...

Страница 44: ...O DO SO CAN CAUSETHE SHOCK FASTENERSTO BECOME LOOSE AND CAUSE PREMATURE COMPONENT DAMAGE 4 Slide the lower shock absorber mount into the bottom cap 5 Install the lower shock absorber mounting fasteners and height control valve linkage bracket if removed 6 Tighten the upper shock absorber mounting locknut to 175 200 foot pounds torque see Figure 8 3 7 Tighten the lower shock absorber mounting lockn...

Страница 45: ...faces for any wear or damage Repair or replace as necessary ASSEMBLY 1 Install the transverse torque rod 2 Install the mounting fasteners and any shims that were removed NOTE Hendrickson recommends the using Grade 8 bolts and Grade C locknuts for all torque rod attachments 3 Prior to tightening ensure that the vehicle is at the proper ride height Refer to vehicle manu facturer for specifications 4...

Страница 46: ...bolt locknuts to torque specifications 3 Tighten all fasteners to the required specification see the Torque Specifications Section of this publication 4 When assembly is complete check the drive axle pinion angles see the Alignment Adjustments Section of this publication 5 Remove the wheel chocks H l J PRIMAAX EX 232 262S 462 692 9 l O Ride Height Shim if equippe Torque Rod Sp 5 a Bolt J 1 _ 5 a W...

Страница 47: ...ition can be retained 2 When replacing a straddle mount bar pin type bushing assembly mark the clocking position of the bushing assembly s bar pin flats with a paint stick on the torque rod end hub prior to disassembly Clocking varies for different model configurations see Figure 8 6 FIGURE 8 6 3 Install the torque rod in the press Support the torque rod end on the receiving tool with the end of t...

Страница 48: ...nstall torque rod assembly as detailed in this section SUPPORT BEAM ASSEMBLY AND CROSSTUBE FIGURE 8 10 FIGURE 8 11 NOTE Effective May 2010 the support beam assembly part numbers 66435 00X or 60831 00X Forging Part Nos 59363 001 65082 000 65284 000 cross tube and previous U beam Assembly Part Numbers with the prefix 66659 XXX for PRIMAAX suspension systems were discontinued see Figure 8 10 The U be...

Страница 49: ...RVICE 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 6 Lower the linkage arm s to exhaust the air in the air springs and deflate the rear suspension IF THE AIR SPRING IS BEING REMOVED FOR AN ALTERNATE REPAIR IT IS MANDATORY TO LUBRICATE THE LOWER AIR SPRING FASTENERS WITH PENETRATING O...

Страница 50: ...Y IS APPROXIMATELY 225 POUNDS CARE SHOULD BE TAKEN AT REMOVAL AND INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS 15 Remove and discard the QUIK ALIGN fasteners 16 Remove QUIK ALIGN eccentric and concentric collars NOTE It may be necessary to use a pry bar to push the U beam assembly out of the frame hangers 17 Remove the U beam assembly from the hangers 18 Remove the U beam assemb...

Страница 51: ...rom front to back see Figure 8 13 9 Remove floor jack supporting the U beam assembly 10 Tighten D Pin locknuts to 275 325 foot pounds torque FIGURE 8 13 11 Install the air spring between the frame and cross tube see Figure 8 12 a PRIMAAX EX Ensure the air spring slot located in the bottom of the air spring engages the beam notch on the top of the support beam b PRIMAAX Ensure the V notch in the en...

Страница 52: ...OOD AGAINST OR CARDBOARD AROUND THE CROSS TUBE CAREFULLY DISLODGE THE CROSS TUBE FROM THE SUPPORT BEAM WITH A LONG HANDLED SLEDGE HAMMER BY APPLYING BLUNT FORCE ON THE SUPPORT BEAM DIRECTLY IN FRONT OF THE INBOARD TOP CORNER JOINT ALL BLUNT FORCE MUST BE APPLIED FLUSHTOTHETHICKEST PART OFTHE SUPPORT BEAM SEE FIGURE 8 14 FAILURE TO STRIKE THE SUPPORT BEAM SQUARELY MAY RESULT IN COMPONENT DAMAGE PRE...

Страница 53: ...n the support beam check for any damage to the support beam bore replace as necessary ASSEMBLY 1 Place the support beam in a shop press on the receiving tool with the beveled edge of the D Pin bore facing up Both ends of the support beam must be supported squarely on the press bed 2 Lubricate the support beam D Pin bore and the D Pin bushing retaining sleeve with chassis grease see Figure 8 17 3 L...

Страница 54: ...LIGN collar is removed from which frame hanger location to facilitate the assemble process Any eccentric with the square drive feature QUIK ALIGN collar should be mounted on the outboard side of the frame hanger Axle thrust angles can only be corrected on frame hangers equipped with eccentric QUIK ALIGN collars 6 Verify the correct QUIK ALIGN collar eccentric concentric is in the correct location ...

Страница 55: ...ATIONAFTER PROLONGED CONTACT MAY BE HARMFUL IF SWALLOWED AVOID DIRECT CONTACT WEAR PERSONAL PROTECTIVE EQUIPMENT CHEMICAL RESISTANT GOGGLES GLOVES CLOTHING TO PREVENT DIRECT CONTACT WITH SKIN AND EYES USE ONLY INWELLVENTILATEDAREAS OPEN DOORSANDWINDOWS DURING USE USEA PROPERLY FITTED NIOSH RESPIRATOR IF VENTILATION IS POOR WASHTHOROUGHLY WITH SOAP AND WATER AFTER USE REMOVE CONTAMINATED CLOTHING A...

Страница 56: ...ners and tighten to 20 30 foot pounds torque 25 Install the wheels and remove the axle support s 26 See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system 27 Connect the height control valve linkage assembly to the height control valve arm s to inflate the suspension 28 Remove the frame support 29 Re...

Страница 57: ...h 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 100 F see Figure 8 28 2 Position the support beam on the receiving tool with the beam eye centered on the tool Be sure the support beam is squarely supported on the press bed 3 Place the QUIK ALIGN bushing installer tool see Special Tools Section of this public...

Страница 58: ...m s to exhaust the air in the air springs and deflate the rear suspension SERVICE HINT Note the quantity of shims removed to maintain the correct pinion angle of the axle at assembly See Alignment Adjustments Section of this publication 6 Remove the fasteners from the longitudinal torque rod to top pad joint and shims if equipped see Figure 8 31 NOTE Due to certain pinion angle configurations the ...

Страница 59: ...olt fasteners NOTE U bolt clamp group hardware for PRIMAAX EX PRIMAAX suspensions are 16 UNF Grade C locknuts and 16 UNF Grade 8 U bolts which are phosphate and oil coated FIGURE 8 33 4 Tighten the U bolt locknuts evenly in 50 foot pounds increments in the proper pattern to achieve uniform bolt tension see Figure 8 33 5 Rap the top of the U bolts with a dead blow mallet and retighten to the proper...

Страница 60: ... sliding the rubber grommet off the height control valve arm s stud PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDERTHE VEHICLE AND AROUNDTHE SERVICE AREA FAILURETO DO SO CAN CAUSE SERIOUS PERSONAL INJURY DEATH OR PROPERTY DAMAGE 5 See additional Air Spring Cautions and Warnings in the Important Safety Notice Sect...

Страница 61: ...emove and discard the lower shock absorber mounting fasteners FIGURE 8 36 14 Pivot the lower shock mount out of the bottom cap 15 Remove and discard the S cam support bracket fas teners and support bracket if equipped see Figure 8 36 16 Remove and discard the U bolt fasteners from the clamp group 17 Remove the bottom cap and inspect for damage or wear Replace as necessary ASSEMBLY 1 Install the to...

Страница 62: ...IGURE 8 38 Bottom Cap Assembly TOP VIEW Brake Flange Cross Tube Support Beam U beam Assembly Axle SERVICE HINT It may be necessary to raise the front of the differential to allow the D Pins to engage the bottom cap 6 Raise the U beam assembly until the D Pins engage in the bottom cap 7 Install the D Pin fasteners with the bolt heads on the forward side of the bottom cap see Figure 8 34 8 Lower the...

Страница 63: ...HAND TOOLS install the lower mounting fasteners and tighten to 20 30 foot pounds torque 18 Install the wheels and remove axle support 19 Remove the jack stands and lower the frame of vehicle 20 See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system 21 Connect the height control valve linkage s to the...

Страница 64: ...NGERS CONNECTED TO THE FRAME AND IT IS ALSO NECESSARY THAT THE SUPPORT BEAMS AND THE LONGITUDINAL TORQUE RODS ARE ATTACHED TO THE REMAINING FRAME HANGERS FAILURE TO DO SO COULD CAUSE THE AXLE TO SHIFT RESULTING IN POSSIBLE DAMAGE TO COMPONENTS OR PERSONAL INJURY SERVICE HINT Increasing the pinion angle may facilitate the disassembly assembly of the frame hanger To increase the pinion angle place a...

Страница 65: ...me hanger to the vehicle per vehicle manufac turer s specifications 9 Remove the frame hanger 10 Inspect mounting surface for any damage or wear replace as necessary 11 Inspect the QUIK ALIGN pivot bushing and torque rod bushings for wear or damage replace as necessary ASSEMBLY 1 Slide the new frame hanger over the support beam QUIK ALIGN bushing 2 Install the new fasteners that attach the frame h...

Страница 66: ...l Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to deflating or inflating the air system 6 Connect the height control valve linkage s to the height control valve arm s to inflate the suspension 7 Remove frame supports s 8 Verify that the axle is in proper alignment See Alignment Adjustments Section of this publication NOTE It is mandatory to have...

Страница 67: ...ifications PRIMAAX EX 232 462 692 9 10 Ride Height 3 525 575 j i _ __ _ _ 4 275 325 ii RE TORQUE NOT rar nper Resistant EQUIRED to integrated op attached SIKAFLEX 22lend cap bolts with around th sealant applied ecap Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 68: ...UNF 275 325 5 U bolt Locknuts 8 16 UNF 350 400 6 Upper Shock Absorber to Shock Bracket 2 10 UNC 175 200 7 Lower Shock Absorber to Bottom Cap 2 5 8 11 UNC 200 225 8 Air Spring Assembly to Upper Air Spring Bracket 2 13 UNC 20 30 9 Air Spring Assembly to Lower Air Spring Mounting Bracket 4 13 UNC 20 30 10 S cam Support Bracket to Bottom Cap Mount 4 3 8 16 UNC 30 40 11 S cam Support Bracket U bolt Loc...

Страница 69: ...k Vehicles PRIMAAX EX 232 462 692 13 Ride Height 0 2b j 525 575 i i 4 275 325 R E TC TO RQ U E N0 1 L Tamper Resistant EQUIRED to integrated op attached SIKAFLEX 22lend cap bolts with around th sealant applied ____________ _ ecap H l J Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 70: ...ing 4 16 UNF 275 325 5 U bolt Locknuts 8 16 UNF 350 400 6 Upper Shock Absorber to Shock Bracket 2 10 UNC 175 200 7 Lower Shock Absorber to Bottom Cap 2 5 8 11 UNC 200 225 8 Upper Air Spring Assembly 2 13 UNC 20 30 9 Air Spring Assembly to Upper Frame Bracket 2 16 UNF 30 40 10 Air Spring Assembly to Lower Air Spring Mounting Bracket 4 13 UNC 20 30 11 S cam Support Bracket to Bottom Cap Mount 4 3 8 ...

Страница 71: ...FOOT POUNDS PRIMAAX EX PRIMAAX for International Truck Vehicles PRIMAAX 230 460 690 9 Ride Height 0 l 0 230 I fl IISIY 0W i i i i i i i i i i i I j I 7 175 200 _____ 9 8 20 30 H l J Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 72: ...ssembly to End Cap 2 7 8 9 UNC 525 575 6 U bolt Locknuts 8 16 UNF 350 400 7 Upper Shock Absorber to Shock Bracket 2 10 UNC 175 200 8 Lower Shock Absorber to Bottom Cap 2 5 8 11 UNC 200 225 9 Air Spring Assembly to Lower Air Spring Mounting Bracket 4 13 UNC 20 30 10 S cam Support Bracket to Bottom Cap Mount 4 3 8 16 UNC 30 40 11 S cam Support Bracket U bolt Locknuts 4 5 16 18 UNC 20 30 NOTE Quantit...

Страница 73: ...tional Truck Vehicles PRIMAAX EX 262S 9 Ride Height 3 525 575 2 190 230 J i 4 0 275 325 RE TORQUE NOT Tamper Resisto tREQUIRED to integrated ennd Cop attached SIKAFLEX 221 cop bolts with around th sealant applied ecop H l J Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

Страница 74: ... 275 325 5 U bolt Locknuts 8 16 UNF 350 400 6 Upper Shock Absorber to Shock Bracket 2 10 UNC 175 200 7 Lower Shock Absorber to Bottom Cap 2 5 8 11 UNC 200 225 8 Air Spring Assembly to Upper Frame Bracket 2 16 UNF 30 40 9 Air Spring Assembly to Lower Air Spring Mounting Bracket 4 13 UNC 20 30 10 S cam Support Bracket to Bottom Cap Mount 4 3 8 16 UNC 30 40 11 S cam Support Bracket U bolt Locknuts 4 ...

Страница 75: ... necessary Excessive driveline vibration Incorrect pinion angle s Adjust pinion angle s refer to the vehicle manufacturer for specifications Loose QUIK ALIGN attachment Replace QUIK ALIGN connection and check vehicle alignment Adjust if necessary Check frame hanger for wear around QUIK ALIGN plates and replace if necessary Ride height set incorrectly Adjust ride height to proper setting See Ride H...

Страница 76: ...ntenance Section of this publication If necessary repair air system and check ride height See Ride Height Adjustment in the Alignment Adjustments Section of this publication Air line obstructed or improperly connected Repair air system and check ride height See Ride Height Adjustment in the Alignment Adjustments Section HCV dump port activated Check HCV dump port for proper connection and function...

Страница 77: ...Hendrickson USA L L C All Rights Reserved 17730 283 Rev A 06 12 Printed in United States of America Truck Commercial Vehicle Systems 1 866 755 5968 Toll free U S and Canada 800 South Frontage Road 630 910 2800 Outside U S and Canada Woodridge IL 60517 4904 USA Fax 630 910 2899 HlllENDRICKSON Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 407 872 1901 parts eprogear com ...

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