TRUCK AIR SUSPENSIONS TECHNICAL BULLETIN

No: 97117-109

Subject: PRIMAAX GEN II MAINTENANCE MANUAL

Date: MARCH 2020 Revision: P

TABLE OF CONTENTS

SECTION 1 Introduction ......................................................................................................................................... 2

SECTION 2 Product Description ........................................................................................................................... 3
SECTION 3 IMPORTANT SAFETY NOTICE .......................................................................................................... 4
SECTION 4 Preventative Maintenance ................................................................................................................. 8
Visual Inspection ................................................................................................................................. 8
U Bolts ................................................................................................................................................. 9
Longitudinal and Transverse Torque Rods ....................................................................................... 10
Shock Absorber Inspection ............................................................................................................... 11
Shock Absorber Visual Inspection Procedure ................................................................................... 11
SECTION 5 Alignment & Adjustments ................................................................................................................ 12
Ride Height Adjustment..................................................................................................................... 12
Lateral Alignment .............................................................................................................................. 14
Rear Axle Alignment.......................................................................................................................... 14
Pinion Angle ...................................................................................................................................... 17
Pinion Angle Adjustment ................................................................................................................... 18
Alignment Instructions ....................................................................................................................... 18
SECTION 6 Component Replacement ................................................................................................................ 19
Fasteners .......................................................................................................................................... 19
Air Spring ........................................................................................................................................... 19
Height Control Valve ......................................................................................................................... 20
Shock Absorbers ............................................................................................................................... 21
Longitudinal Torque Rod ................................................................................................................... 21
Transverse Torque Rod .................................................................................................................... 22
Transverse Torque Rod Bush ........................................................................................................... 22
Support Beam Assembly and Cross Tube ........................................................................................ 23
D-Pin Bush ........................................................................................................................................ 25
Quick-align Pivot Bush ...................................................................................................................... 25
Top Pad ............................................................................................................................................. 26
Bottom Cap ....................................................................................................................................... 27
Axle Bump Stops ............................................................................................................................... 29
Frame Hanger ................................................................................................................................... 29
SECTION 7 Plumbing Diagram ............................................................................................................................ 31
SECTION 8 Torque Specifications ...................................................................................................................... 32
SECTION 9 Trouble Shooting Guide ................................................................................................................... 33

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PRIMAAX® Gen II Maintenance

SECTION 1 Introduction
This publication is to acquaint and assist maintenance personnel in the preventative
maintenance and rebuild of the PRIMAAX® Generation II suspension systems as
supplied from Australia to the Asia Pacific region.

NOTE: Use only Genuine Hendrickson parts for servicing this suspension system. Most
Hendrickson parts can be identified by the Hendrickson trademark.

It is important to read and understand the entire Technical Bulletin prior to

performing any maintenance, service, repair, or rebuild of the product. The
information in this publication contains safety information, product specifications,
features, maintenance, service, repair and rebuild instructions for the PRIMAAX®
Suspension.

Hendrickson reserves the right to make changes and improvements to its products
and publications at any time. For more information or to check for the latest version
of this manual go to www.hendrickson.com.au

Frame Hanger

Clamp Group
Main Beam

Longitudinal Torque Rod

Cross Tube

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PRIMAAX® Gen II Maintenance

SECTION 2 Product Description

Figure 2-1
Heavy Duty Torque Rods used
for longer service life
Reduced maintenance cost and increased
uptime of your vehicle.
No Lubrication requirements, heavy-duty Large volume air springs
incorporated to reduce noise,
rubber bushes used to improve service life
vibration and harshness to
cab, chassis and body
equipment for reduced total
vehicle maintenance

Proven Quick- Align

Adjusters

PAX 230 PAX 460 PAX 520

Capacity 10,500 kg 18,000 kg 22,000 kg

Axle Configuration1 Single Tandem Tandem

GCM Approval2 80,000 kg 120,000 kg 140,000 kg

Axle Travel3 150 mm 150 mm 150 mm

Ground Clearance 273 mm 273 mm 273 mm

Ride Height4 200-273 mm 200-273 mm 200-273 mm

Engine Restrictions None None None

▄ PRIMAAX® approved for vocational and heavy-haul vehicle applications including, but not
limited to:
Truck, Prime Mover, Tipper, Road Train, Agitator, Refuse, Logging, Fire/Rescue, Speciality and
vehicles equipped with outriggers — contact Hendrickson or original equipment manufacturer
for additional applications and information.
▄ Patent pending
Notes:
1. Installed weight includes complete suspension, torque rods, axle and frame brackets, and all
hardware. Published weight is for standard PRIMAAX® suspension. Other configurations may
change weight.
2. Contact Hendrickson or vehicle manufacturer for applications that may exceed GVW/GCW
approval ratings.
3. Axle travel may be limited by vehicle manufacturer; axle stop settings may restrict suspension’s
articulation.
4. For different options, please contact Hendrickson or Authorised OEM for further information.

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PRIMAAX® Gen II Maintenance

SECTION 3 IMPORTANT SAFETY NOTICE

Proper maintenance, service and repair are important to 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.

The warnings and cautions should be read carefully to help prevent personal injury and to
assure that proper methods are used. Improper maintenance, service or repair may cause
personal injury, render the vehicle unsafe in operation, cause damage to the vehicle, or
void manufacturer's warranty.

Failure to follow the safety precautions in this manual can result in personal injury and/or
property damage. Carefully read and understand all safety related information within this
publication, on all decals and, that provided by the vehicle manufacturer before conducting
any maintenance, service or repair.

EXPLANATION OF SIGNAL WORDS

Hazard “Signal Words” (Danger-Warning-Caution) appear in various locations throughout
this publication. Information accented by one of these signal words must be observed to
help minimise the risk of personal injury to service personnel, or possibility of improper
service methods which may render it unsafe or damage the vehicle.

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.

NOTE: An operating procedure, practice condition, etc. which is essential to emphasise.

SERVICE HINT: A helpful suggestion which will make the servicing being performed a little easier and/or
faster. Also note that some service operations may require the use of special tools
designed for specific purposes.
! WARNING FASTENERS
LOOSE OR OVER TORQUED FASTENERS CAN CAUSE SEVERE PERSONAL INJURY,
COMPONENT DAMAGE, LOSS OF VEHICLE CONTROL OR PROPERTY DAMAGE, MAINTAIN
CORRECT TORQUE VALUE AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS
AS SPECIFIED, USING A TORQUE WRENCH THAT IS REGULARLY CALIBRATED.
! WARNING LOAD CAPACITY
ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION. ADD-ON AXLE
ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES 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.
! WARNING MODIFYING COMPONENTS
DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORISATION FROM HENDRICKSON.
DO NOT SUBSTITUTE PARTS OF THE SUSPENSION. USE OF MODIFIED OR REPLACEMENT
PARTS NOT AUTHORISED BY HENDRICKSON MAY NOT MEET HENDRICKSON'S
SPECIFICATIONS, AND CAN RESULT IN COMPONENT DAMAGE,
LOSS OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.
USE ONLY HENDRICKSON AUTHORISED REPLACEMENT PARTS.

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PRIMAAX® Gen II Maintenance

! WARNING TORCH/WELDING
DO NOT USE A CUTTING TORCH TO REMOVE ANY ATTACHING FASTENERS. THE USE OF
HEAT ON SUSPENSION COMPONENTS MAY ADVERSELY AFFECT THE STRENGTH OF
THESE PARTS. EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING
MAINTENANCE IN THE AREA OF THE SUPPORT BEAM.
DO NOT CONNECT ARC WELDING GROUND LINE TO THE SUPPORT BEAM. DO NOT STRIKE
AN ARC WITH THE ELECTRODE ON THE SUPPORT BEAM AND AXLE. DO NOT USE HEAT
NEAR THE SUPPORT BEAM ASSEMBLY. DO NOT NICK OR GOUGE THE SUPPORT BEAM.
SUCH IMPROPER ACTIONS CAN DAMAGE THE SUPPORT BEAM. THE ASSEMBLY COULD
FAIL, AND CAUSE POSSIBLE PERSONAL INJURY, LOSS OF VEHICLE CONTROL AND OR
PROPERTY DAMAGE.

! WARNING WORK SITE DUMPING

WHEN THE BED OF THE TRUCK/TRAILER IS TILTED, IT IS MANDATORY TO COMPLETELY
EXHAUST THE AIR FROM THE SUSPENSION SYSTEM TO HELP PROVIDE STABILITY ON
UNEVEN TERRAIN. FAILURE TO DO SO COULD RESULT IN LOSS OF VEHICLE CONTROL,
POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

! WARNING 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 JEOPARDISED 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.

! WARNING SHOCK ABSORBERS

THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SUSPENSION.
ANYTIME THE AXLE ON A PRIMAAX® SUSPENSION IS SUSPENDED IT IS MANDATORY THAT
THE 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.

! WARNING PERSONAL PROTECTIVE EQUIPMENT

ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL
PROTECTIVE EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING
VEHICLE MAINTENANCE, REPAIR OR SERVICE.

! WARNING AIR SPRING INFLATION

DO NOT INFLATE AIR SPRING ASSEMBLY WHEN IT IS UNRESTRICTED. ASSEMBLY MUST BE
RESTRICTED BY THE SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE
BEYOND PRESSURES OF 690 kPa AT DESIGN RIDE HEIGHT.
CONTACT HENDRICKSON TECH SERVICES FOR DETAILS. IMPROPER USE OR OVER
INFLATION CAN CAUSE ASSEMBLY TO BURST CAUSING SEVERE PERSONAL INJURY
PROPERTY AND/OR COMPONENT DAMAGE.

! CAUTION INFLATE THE SUSPENSION SLOWLY AND MAKE SURE THAT THE RUBBER BLADDER OF
THE AIR SPRING INFLATES UNIFORMLY AND IS NOT BINDING. FAILURE TO DO CAN CAUSE
DAMAGE TO THE UPPER AIR SPRING MOUNTING BRACKET AND VOID WARRANTY.

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PRIMAAX® Gen II Maintenance

! WARNING AIR SPRING DEFLATION

AIR SPRINGS MUST BE DEFLATED PRIOR TO LOOSENING ANY CLAMP GROUP
HARDWARE. UNCONSTRAINED AIR SPRINGS WILL VIOLENTLY SHIFT, RESULTING IN
PERSONAL INJURY, DEATH OR PROPERTY DAMAGE.
IF THE AIR SPRING IS BEING 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.

! WARNING PARTS CLEANING

SOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS, AND CAUSE BURNS. TO HELP
AVOID SERIOUS PERSONAL INJURY, CAREFULLY FOLLOW THE MANUFACTURER’S
PRODUCT INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURES:
1. WEAR PROPER EYE PROTECTION.
2. WEAR CLOTHING THAT PROTECTS YOUR SKIN.
3. WORK IN A WELL-VENTILATED AREA.
4. DO NOT USE SOLVENTS THAT 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
MACHINED OR POLISHED PARTS. DOING SO WILL CAUSE DAMAGE TO THE PARTS AND
VOID WARRANTY.

! WARNING QUIK-ALIGN FASTENERS

DO NOT ASSEMBLE QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY
DACROMET PLUS XL PLATED FASTENERS TO SUSTAIN PROPER CLAMP FORCE. FAILURE
TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL
INJURY.
ENSURE THAT QUIK-ALIGN FASTENER TORQUE VALUES ARE SUSTAINED AS
RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS PUBLICATION.
FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL RESULTING IN PERSONAL
INJURY OR PROPERTY DAMAGE.
! WARNING SUPPORT BEAM AND CROSS TUBE ASSEMBLY
DO NOT STRIKE SUSPENSION COMPONENTS WITH
A HAMMER. HOWEVER, THE SUPPORT BEAM
AND CROSS TUBE JOINT REQUIRES BLUNT FORCE
ON THE SUPPORT BEAM AT THE JOINT TO DISLODGE
THE TWO COMPONENTS. Do not strike the
ALL BLUNT FORCE MUST BE APPLIED FLUSH TO support beam
flanges nor jack the
THE THICKEST PART OF THE SUPPORT BEAM AT
vehicle from the
THE INBOARD CORNER JOINT. FAILURE TO Support Beam
STRIKE THE SUPPORT BEAM SQUARELY MAY
RESULT IN COMPONENT DAMAGE, PREMATURE FAILURE AND VOID WARRANTY.

! WARNING CROSS TUBE ASSEMBLY

IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE AND RESULT IN LOSS
OF VEHICLE CONTROL, SEVERE PERSONAL INJURY OR DEATH AND WILL VOID
HENDRICKSON'S WARRANTY.

▄ DO NOT USE THE SUSPENSION SUPPORT BEAM OR THE CROSS TUBE AS A

JACKING POINT.
▄ REFER TO VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.

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PRIMAAX® Gen II Maintenance

! WARNING SAFETY DECALS

REPLACE ANY SAFETY DECALS THAT ARE FADED, TORN, MISSING, ILLEGIBLE, OR
OTHERWISE DAMAGED. CONTACT YOUR DEALER TO ORDER REPLACEMENT LABELS.

Figure 3-2

Figure 3-3
IMPROPER JACKING

Figure 3-4
PROPER JACKING AT THE DIFFERENTIAL ASSEMBLY

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PRIMAAX® Gen II Maintenance

SECTION 4 Preventative Maintenance

Visual Inspection
A visual inspection of the suspension should be performed every 25,000 km or
every six months, whichever comes first. To help ensure all components function to
their highest efficiency, any component seen to be loose or damaged should be re-
tightened to the specified torque requirements or replaced as necessary.

Interval Kilometres Action

Original Equipment Nil Torque all fasteners
Manufacturer Installation
Pre-Delivery Inspection Nil Inspect and check torque of all fasteners
Initial Dealer Service 4,500 Inspect and check torque of all fasteners
25,000 Kilometre Service 25,000 Visual Inspection of Suspension System
50,000 Kilometre Service 50,000 Inspect and check torque of all fasteners
▄ Wear and Damage — Inspect all parts of the suspension for wear and
damage. Look for bent or cracked parts. Replace all worn or damaged
parts.

▄ Air Spring — Look for chafing 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. Up to
46 mm of slippage in either direction is acceptable. Replace all worn or
damaged parts.

▄ Fasteners—Look for any loose or damaged fasteners on the entire

suspension. If any fasteners are found to be loose or damaged, replace or
tighten to the torque value within the specified torque range. See Torque
Specification Chart in this publication for recommended torque
requirements.
Use a calibrated torque wrench to torque in a tightening direction. As soon
as the fastener starts to move, record the torque then correct the torque to
the specified torque range. Replace any worn or damaged fasteners with
genuine specified fasteners.

▄ Support Beam Assembly—Check the overall condition of the support

beam for dents, dings, or other damage on the outer edges of the support
beam flanges. Check the D-Pin bushes for tearing or extreme bulging.
Check for any metal to metal contact in the bushed joints. Replace all
worn or damaged parts.

▄ Frame Hanger Bracket — Check for any signs of loosening or damage at

the Quick-Align connections or longitudinal torque rod connections.
Replace all worn or damaged parts.

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PRIMAAX® Gen II Maintenance

▄ Cross Tube — Check for cracks, damage, metal shavings, or looseness

at the beam connection. Replace all worn or damaged parts.

▄ Torque Rods — All torque rods must be inspected for looseness, torn or
shredded rubber, and for proper torque. If there is metal to metal contact
in the bush joint, this is a sign of excessive bush wear and the bush needs
to be replaced. Replace all worn or damaged parts.

▄ Shock Absorbers — Look for any signs of dents or leakage. Misting is

not considered a leak. See Shock Absorber Inspection Procedures.

▄ Tyre Wear — Inspect the Tyres for wear patterns that may indicate
suspension damage or misalignment. Replace all worn or damaged parts.

▄ Height Control Valve and Air Lines — Check ride height is set to
specifications. Check the suspension air system for air leaks. Check all air
lines for proper routing. Check for chafing or pinched air lines. Check the
height control valve linkage for damage or interference with peripheral
components. Replace all worn or damaged parts.

U Bolts
1. U Bolt locknuts must be torqued to specification at pre-delivery.
2. U Bolt locknuts must be re-torqued at 1,500 Km.
3. U Bolt locknuts must be re-torqued at 4,500 Km.
4. Thereafter follow the 1 year/50,000 Kilometre inspection and re-torque interval.

Current Hendrickson Truck Suspension Systems U Bolt locknuts for the

PRIMAAX® suspension are 3/4” -16 UNF and are phosphate and oil coated.

SERVICE HINT: Due to certain pinion angle configurations, the removal of the D-pin bolts
may be necessary to access the U bolt locknuts

Figure 6-1
Tighten the U Bolt locknuts evenly to 440 Nm (325
ft/lb) torque in the correct sequence and in increments
of 135 Nm (100 ft/lb). As shown in figure 6-1.

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PRIMAAX® Gen II Maintenance

Longitudinal and Transverse Torque Rods

All torque rods should be inspected for looseness, torn or shredded rubber, and
proper fastener torque checked in accordance to the maintenance schedule.

To inspect for looseness, torn or shredded rubber with the brakes applied, slowly
rock an empty vehicle with power while a mechanic visually checks the action at
both ends. Or with the vehicle shut down, a lever check can be made with a long
pry bar placed under each rod end and pressure applied.

Figure 6-2

The tapered stud attaching

fasteners are furnished by
Hendrickson. The straddle
mount torque rod end attaching
fasteners are furnished by the
vehicle manufacturer. It is
important that the tightening
torque of the nuts be checked
during normal preventative
maintenance scheduled.
Follow the vehicle manufacturer’s specifications for tightening torque values.

The length of the longitudinal torque rods is determined by the truck manufacturer
for optimum drive line angles. The longitudinal torque rods along with the bottom
caps maintain these angles and control acceleration and brake forces.
The length of the transverse rods is also determined by the vehicle manufacturer in
order to centre 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 torque rod and the transverse
torque rod frame bracket or between the transverse torque rod and axle tower
bracket. Refer to vehicle manufacturer for proper shim location, also see Lateral
Alignment in the Alignment Section of this publication.

The transverse torque rods also control axle walk-out during cornering.

The mounting brackets at the axle housing end of the torque rods are furnished
and welded into position on the axle housings by the axle or vehicle manufacturer.

Both types of torque rods, transverse and longitudinal may have attaching ends
designated “straddle mount,” “tapered stud,” or "through bolt".

Whether the rod ends are straddle mount, through bolt, or tapered stud, torque rod
bushes can be renewed by pressing out the worn end and installing a replacement
bush. See Component Replacement section in this publication.

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PRIMAAX® Gen II Maintenance

Shock Absorber Inspection

Figure 6-4

HEAT TEST
1. Drive the vehicle at moderate speeds for fifteen
minutes.
2. Use a Heat Gun aimed at below the dust cover.
3. Aim at the frame to get an ambient temperature
Reference
4. A warm shock absorber indicates that it has
dampening force and is working, a cold shock
absorber should be replaced.

! WARNING DO NOT TOUCH THE SHOCK ABSORBER AS IT

COULD POSSIBLY CAUSE PERSONAL INJURY.

Shock Absorber Visual Inspection Procedure

Figure 6-5
Inspect the shock absorbers fully extended.
Shock absorbers will need to be replaced for
any of the following:
1. Damaged upper or lower mounting eyes.
2. Damaged upper or lower bush.
3. Damaged dust cover and/or shock body.
4. Leaking shock absorber, when streams of
fluid travel down the side of the shock
absorber, particularly from the upper seal,
this seal will allow for misting to appear on the shock body (misting is not a leak
and is considered acceptable).
5. Shock absorber is damaged internally, jammed in the collapsed position. It can
also be determined by removing the shock, shake and listen to the sound of
metal parts rattling inside the shock body.
6. Worn internal valving or dampening mechanisms.

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PRIMAAX® Gen II Maintenance

SECTION 5 Alignment & Adjustments

Ride Height Adjustment

The PRIMAAX® suspension is equipped with a height control valve located on the front drive axle. Please
refer to the Plumbing Diagram Section in this publication.

1. Use a work bay with a level floor. Drive the vehicle slowly, straight ahead. Move the vehicle in a
forward and reverse motion to release any potential loads on the suspension prior to final
positioning. End with all wheels positioned straight ahead. Try to roll to a stop without the
brakes being used.

2. Chock the front wheels of the vehicle. Do not set the parking brake.

3. Verify that the air system is at full operating pressure

4. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication prior to
deflating or inflating the air system. Cycle the air system. Disconnect the levelling valve arm(s)
from the rubber grommet. Lower the levelling valve arm to exhaust the air in the air springs and
deflate the suspension. Reconnect the levelling valve arm to the control rod to inflate the
suspension.

Figure 7-1

15 Nm

5. Using a tape measure, measure the referenced vertical ride height on the front the centreline of
axle to the underside of the chassis rail. This measurement is to be 254 mm (10 inches).

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PRIMAAX® Gen II Maintenance

Figure 7-2 Standard Ride Height

Ride height of
254 mm is Do not use shock
measured from absorber length
the centre of the as a ride height
axle to the measurement
underside of the
chassis

6. If an adjustment is required, verify that the air system is at full operating pressure.

7. Refill the suspension by raising the height control valve arm by hand, so that the air springs are
above the proper ride height.

8. Lower the levelling valve arm to exhaust the air system until the suspension is at proper ride
height.
Figure 7-4
9. Use a 4.5 mm wooden dowel rod (golf tee) to
set the neutral position for the height control
valve by aligning the hole in the levelling arm
with the hole in the height control valve
cover.

DO NOT use a metal rod or nail as this may

cause damage to the height control valve.

10. Adjust the extension rod so rod can be reconnected to the height control valve arm at the
proper height.

11. Connect the height control valve arm to the rod.

12. Adjust the rod to this valve arm setting and tighten locking nut.

13. Remove the dowel from the height control valve.

14. If equipped with a suspension dump system in the cab, cycle the suspension air system by
using the cab dump valve control. If not equipped, cycle the height control valve levelling arms
stated in step number 4.

15. Recheck the ride height.

16. Repeat steps 3 through 14 until the ride height is within specification.

SERVICE HINT: It is very important that the levelling valve be cycled completely before and after any
ride height adjustments. The cycling of the levelling valve will help to make the
adjustment more accurate.

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PRIMAAX® Gen II Maintenance

Lateral Alignment
If it is necessary to check the lateral alignment, measure from the outside of the frame rail to the
rim flange of the inner tyre. Record the measurement. Measure the same distance on the opposite
side of the same axle. Record the measurement. Subtract the two measurements to get a
difference between the two. If the difference is greater than 3 mm (1/8") it will be necessary to
correct the lateral alignment. This is accomplished by adding or removing shims that are located
between the transverse torque rod and the bottom cap. A general rule of thumb is to use a shim
with a thickness that is half of the difference between the two measurements.

Example: If the lateral alignment is out of specification by 10 mm, remove or install a 5 mm shim.

The 5/8" mounting fasteners used with the straddle mount transverse torque rod are furnished by
the vehicle manufacturer. It is important to check the locknuts for proper torque specification during
preventative maintenance service intervals.

Follow the vehicle manufacturer's specifications for tightening torque values.

All torque rods should be inspected for looseness, torn or shredded rubber, and proper torque
every six months. A lever check can be made with a long pry bar placed under each rod end and
pressure applied.
Rod ends can be renewed by pressing out the worn bush and installing a replacement bush. In the
event of structural damage, the entire torque rod assembly should be replaced. The torque rods
are made to a specified length or a two-piece torque rod that can be cut and welded to the desired
length if available.

Rear Axle Alignment

Proper alignment is essential for maximum ride quality, performance, and tyre service life.
The recommended alignment procedure is described below. This procedure should be performed if
excessive or irregular tyre wear is observed, or any time the QUIK-ALIGN connection is loosened
or removed.

1. Use a work bay with a level floor. Drive the vehicle slowly, straight ahead. Move the vehicle
in a forward and reverse motion to release any potential loads on the suspension prior to
final positioning. End with all wheels positioned straight ahead. Try to roll to a stop without
the brakes being used.
2. Chock the front wheels of the vehicle. Do not set the parking brake.
3. Verify that the proper ride height is set. For the proper ride height instructions see Ride
Height Adjustment in this publication.
4. If axle alignment equipment is not available, using "C" clamps, securely clamp a six foot
piece of STRAIGHT bar stock or angle iron across the lower frame. Select a location for
the angle iron as far forward of the drive axle as possible where components will not
interfere.

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PRIMAAX® Gen II Maintenance

Figure 7-6

5. Accurately square the straight edge to the frame using a carpenter’s square.

6. Using a measuring tape, measure from the straight edge to the forward face of the front drive
axle arms at the centreline on both sides of the vehicle as shown in Figure 7-6, A and B. If
both sides measure within the vehicle manufacturer’s specifications, alignment of the front
drive axle is acceptable.

7. If the front drive axle is within specification, proceed to check the rear drive axle.

8. Using a trammel bar measure from spindle centre to spindle centre on both sides of the
vehicle. See Figure 7-6, C and D. If both sides measure within original equipment
manufacturer’s specifications, alignment of the rear drive axle is acceptable.

9. If not within specifications, perform alignment correction procedure.

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PRIMAAX® Gen II Maintenance

Figure 7-7

10. To allow the axle to move freely, it is important to have all QUIK–ALIGN pivot bolt locknuts
snugged tight on the axle that is being aligned. This will hold the eccentric flanged collar in
place against the hanger face, and within the adjustment guide, but loose enough to permit
the eccentric flanged collar to rotate freely.

11. The 3/4” longitudinal torque rod to frame hanger locknuts must be loose to allow the axle to
move during the alignment process. These are re-shimmed at the end of the procedure, see
Fig 7-13. All other suspension fasteners must be tightened to their specified torque values.

Figure 7-8 Figure 7-9

12. Use a QUICK-ALIGN Socket tool (Refer to the 97114-070 parts list for all special tools
available) and Impact Gun (Figure 7-8 and 7-9), or a 3/4” square drive socket and breaker
bar to rotate the QUIK-ALIGN eccentric collar to align the axle. A 180º rotation of the QUIK-
ALIGN collar, from the full forward position, will move the axle rearward up to a maximum of
25 mm. A general rule of thumb is to adjust half the distance out of specification.

Example: 10 mm out of specification would require a 5 mm adjustment of the QUIK-ALIGN

to bring the axle square to the centreline of the vehicle.

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Figure 7-10 Figure 7-11 Figure 7-12

Axle Full Forward Position Axle Full Aft Position Axle Centre Position

13. Once the correct axle alignment is achieved, use a calibrated torque wrench to tension the
QUIK-ALIGN locknuts to the specified value to complete the alignment.

14. Re-check the ride height and the axle alignment to verify that it is within specifications; see
Rear Axle Alignment Inspection Section.

15. Check the pinion angles with a digital protractor. Refer to the vehicle manufacturer
specifications for the required pinion angles. (see Figure 7-13)

16. If the angles are within the vehicle manufacturer’s specifications, fill the gap between the bar
pin torque rod and frame hanger with shims. Torque the longitudinal Rod bolts to the
specified values.

17. If it is necessary to fine tune the pinion angle it is possible to increase or decrease the pinion
angle by using one of the following appropriate procedures.

Pinion Angle
Drive axle pinion angles are established by the vehicle manufacturer. If it is necessary to fine tune
the pinion angle see the Alignment Section of this publication.

To check the pinion angle, verify first that the suspension is at the proper ride height (see Ride
Height Adjustment in this Section). Install a digital protractor on the axle. Check that the pinion
angle is correct to the vehicle manufacturer's specifications.

Figure 7-13

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PRIMAAX® Gen II Maintenance

Pinion Angle Adjustment

FOR LESS THAN 1.5 DEGREES Figure 7-14

Add or remove
Install or remove shims between the shims to
longitudinal torque rod and the frame maintain or
hanger to achieve the recommended adjust pinion
pinion angle.
To increase the pinion angle, install
angle
shims and to decrease the pinion
angle remove shims.
A general rule of thumb is, 1/8"
change in the shim pack thickness will
increase or decrease the pinion angle
by 1/2 degree.

PINION ANGLE ADJUSTMENT

FOR MORE THAN 1.5 DEGREES
If the required change in pinion angle is greater than 1.5 degrees, you must replace the bottom
cap with one that will achieve the desired pinion angle after pinion angle adjustment, use a
calibrated torque wrench to tighten the 3/4” longitudinal torque rod to frame hanger.

Following the alignment of the axles, move the vehicle back and forth several times prior to
removing the straight edge from the frame, and recheck measurements to confirm adjustments.
Repeat steps 1 through 11 until the correct alignment and pinion angle is achieved.

NOTE: Prior to tightening the QUIK-ALIGN locknuts to torque specifications, it is

mandatory that the vehicle is at the proper ride height.

SERVICE HINT: If the axle can be adjusted on both sides, begin the adjustment on the side that is
furthest out of specification.

WARNING DO NOT ASSEMBLE THE 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.
ENSURE THAT THE QUIK-ALIGN FASTENERS TORQUE VALUE IS SUSTAINED AS
RECOMMENDED IN THE TORQUE REQUIREMENTS SECTION OF THIS
PUBLICATION, FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE CONTROL
RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.

Alignment Instructions
NOTE: Use a new QUIK-ALIGN pivot bolt kit (refer to the 97114-070 Parts List) for any axle
alignment or Dismantling 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.

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SERVICE HINT: The Eccentric collars (with the square drive feature) are located on the outboard
side of the frame hangers with the concentric collars on the inboard side. The total
range of forward/rearward axle adjustment is 25 mm.

SERVICE HINT: If the axle can be adjusted on both sides, begin the adjustment on the side that is
furthest out of specification.

NOTE: Prior to tightening the 1" QUIK-ALIGN locknuts to torque specifications, it is

mandatory that the vehicle is at the proper ride height.
Once the correct axle alignment is achieved, use a calibrated torque wrench to
tighten the 1" QUIK-ALIGN locknuts to specified value to complete the alignment.
Re-check the ride height and the axle alignment to verify that it is within
specifications; see Rear Axle Alignment Inspection in this Section.

NOTE: Use a new support beam QUIK-ALIGN pivot bolt kit and a new longitudinal torque
rod QUIK-ALIGN bolt kit, (refer to the 97114-070 Parts List) for any axle alignment or
Dismantling 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.

SECTION 6 Component Replacement

Fasteners
Hendrickson recommends that when servicing the vehicle to replace the removed fasteners
with new equivalent fasteners. Always maintain correct torque values. Check torque values as
specified. Genuine Hendrickson fasteners must be used following the torque specifications
listed in this manual.

Air Spring
Dismantling
1. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication.
2. Chock the wheels.
3. Support the frame.
4. Disconnect the height control valve levelling valve arm from the rubber grommet.
5. Prior to deflating the suspension system. Lower the levelling valve arm to exhaust the air
in the air springs and deflate the rear suspension.
6. Remove the air line from the air spring.
7. If the air spring is being removed for an alternate repair, it will be necessary to lubricate
the lower mounting fasteners with penetrating oil and remove with hand tools from the air
spring. This will prevent the air spring mounting studs from breaking during the removal
process.
8. Remove the lower air spring mounting bracket from the cross tube.
9. Remove the fasteners from the upper air spring mounting bracket and the frame.
10. Remove the air spring.

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Assembly
1. Inspect the mounting surfaces and lower air spring mounting bracket
for any damage, replace if necessary.
2. Install the air spring between the frame and cross tube so that the locating tab indexes the
end cap.
3. Hold the air spring tight against the frame flange and tighten the upper air spring mounting
fastener per original equipment manufacturer’s specifications.
4. Install the lower air spring mounting bracket over the cross tubes, indexing the mounting
studs on the air spring.
5. Install the lower mounting fasteners and tighten to the specified value.
6. Connect the air line to the air spring.
7. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication prior
to inflating the suspension system. Inflate the suspension slowly and verify that the air
spring bladder inflates uniformly without binding.
8. Remove the frame supports.
9. Remove the wheel chocks.

! Warning FAILURE TO PRESS THE AIR SPRING AGAINST THE UNDERSIDE OF THE FRAME
WHILE TIGHTENING THE UPPER AIR SPRING BRACKET CAN RESULT IN
COMPONENT DAMAGE AND PERSONAL INJURY OR PROPERTY DAMAGE.

Height Control Valve

Dismantling
1. Chock the wheels of vehicle.
2. Disconnect the height control valve levelling valve arm from the rubber grommet.
3. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication
prior to deflating the suspension system. Lower the levelling valve arm to exhaust the air
in the air springs and deflate the rear suspension.
4. Remove the air lines from the height control valve.
5. Remove the brass fittings from the ride height control valve.
6. Remove the 1/4" washers and locknuts that attach the ride height control valve to the
frame mounting bracket.
7. Remove the ride height control valve.

ASSEMBLY
1. Install the brass fittings into the height control valve. DO NOT use Teflon tape or pipe
sealing compound.
2. Install the height control valve to the frame mounting bracket by attaching the 1/4"
washers and locknuts.
3. Tighten to the specified value. Install the air lines to the height control valve. Reference
the Plumbing Diagram Section of this publication.
4. Install the height control valve link assembly to the ride height control valve arm. See Air
Spring Cautions and Warnings in the Safety Notice Section of this publication prior to
inflating the suspension system.
5. Inflate the suspension by connecting the height control valve linkage to the height
control valve arm.
6. Cycle the suspension a minimum of 3 times. Verify proper ride height adjustment after
cycling, (see ride height adjustment Preventative Maintenance Section of this
publication).

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Shock Absorbers
DISMANTLING
1. Chock the wheels of the vehicle.
2. Remove the lower shock absorber mounting fasteners.
3. Remove the upper shock absorber mounting fasteners.
4. Slide the shock absorber out of the mounting brackets.
5. Inspect the shock absorber mounting brackets and hardware for damage or wear,
replace as necessary.

ASSEMBLY
1. Install the shock absorber into the upper mounting bracket.
2. Install the upper shock absorber mounting fasteners.
3. Install the lower shock absorber mounting fasteners.
4. Ensure that the vehicle is at the correct ride height prior to setting the shock absorber
mounting bolts to torque.
5. Tighten the upper shock absorber mounting 3/4” locknuts to the specified value.
6. Tighten the lower shock absorber mounting 5/8" locknuts to the specified value.

Longitudinal Torque Rod

DISMANTLING
1. Chock the wheels of the vehicle.
2. Remove the torque rod mounting fasteners and shims (if equipped).
3. Remove the torque rod. Inspect the mounting surfaces for any wear
or damage, replace if necessary.

ASSEMBLY
1. Install the torque rod. Install the mounting fasteners and any shims that were removed.
2. Tighten all fasteners to the required specification; see Hendrickson Recommended
Torque Specifications Section in this publication.
3. Tighten all fasteners to the required specification; see Hendrickson Recommended
Torque Specifications Section in this publication.
4. When assembly is complete check the pinion angle on both sides of the axle housing.
Tighten all fasteners to the required specification; see Hendrickson Recommended
Torque Specifications Section in this publication.

SERVICE HINT: Be aware of the quantity of shims removed to maintain the correct pinion angle of the
axle at assembly. See Alignment Section in this publication.

NOTE: Prior to tightening the 3/4” straddle bush and the 7/8" top pad through bolt locknuts to
the specified torque specifications, it is mandatory that the vehicle is at the proper
ride height.

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Transverse Torque Rod

DISMANTLING
1. Chock the wheels of the vehicle.
2. Remove the torque rod mounting fasteners.
3. Remove the torque rod. Inspect the mounting surfaces for any wear or damage.

ASSEMBLY
1. Install the torque rod. Install the mounting fasteners and any shims that were removed.
2. Prior to tightening ensure that the vehicle is at the proper ride height.
3. Tighten all fasteners to the required torque specification. Refer to original equipment
manufacturer for specifications.
4. Check the lateral axle alignment to verify correct amounts of shims are installed. See
Alignment Section of this publication.

NOTE: Never assume the lateral alignment was correct prior to work commencing.

SERVICE HINT: Be aware of the quantity of shims removed to maintain the correct pinion angle of
the axle at assembly. See Alignment Section in this publication.

Transverse Torque Rod Bush

DISMANTLING
Special tooling required: A vertical press with a capacity of at least 10 tons. A receiving
tool (5" long, 2" inner diameter by 1/4” wall steel tubing).
1. Remove the torque rod as detailed in Component Replacement Section of this
publication.
2. Support the torque rod end on the receiving tool with the end the tube of torque rod
centred on the tool. Ensure the torque rod is squarely supported on the press bed.
3. Push directly on the bush straddle mount bar pin until top of the bush is level to the top
of torque rod end tube. Press until the bush clears the torque rod end tube.
4. Clean and inspect the inner diameter of the torque rod ends, removing any nicks with an
emery cloth or a rotary sander.

ASSEMBLY
1. Lubricate the inner diameter of the torque rod ends and the new rubber bushes with a
suitable installation lubricant, such as P-80 (Hendrickson part number 70867-001). DO
NOT use a petroleum or soap base lubricant, it can cause an adverse reaction with the
bush, such as deterioration of the rubber.
2. Press in the new bushes. Support the torque rod end on the receiving tool with the end
tube of torque rod centred on the receiving tool. The straddle mount bar pin bushes
must have the mounting flats positioned at zero degrees to shank of the torque rod.
3. Press directly on the straddle mount bar pin of bush. The rubber bushes of the bar pin
must be centred within the torque rod end tubes.
4. When pressing in the new bushes, overshoot the desired final position by approximately
5 mm.
5. Press the bush again from opposite side to centre the bar pin within the torque rod end,
Wipe off excess lubricant. Allow the lubricant to dissipate for four hours before operating
the vehicle.
7. Install torque rod assembly as detailed in the Component Replacement section of this
publication.

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DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE THE BUSHES FROM THE TORQUE ROD. THE
USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE ROD, HEAT CAN CHANGE
THE MATERIAL PROPERTIES. A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS
OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

Support Beam Assembly and Cross Tube

Support Beam
Cross Tube

DISMANTLING
1. Chock the front wheels.
2. Support the frame.
3. Support the axle.
4. Remove the tyres on the axle being serviced.
5. Disconnect the levelling valve arm from the control rod.
6. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication
prior to deflating or deflating the suspension system. Lower the levelling valve arm to
exhaust the air in the air springs and deflate the rear suspension.
7. Lubricate the lower mounting fasteners with penetrating oil and remove the fasteners
from the air spring mounting studs.
8. Remove both the lower air spring mounting brackets to disconnect both air springs
from the cross tube.
9. Install a floor jack to support the cross tube and support beam assembly.
10. Loosen the QUIK-ALIGN locknuts, DO NOT remove at this time.
11. Remove all four (4) D-pin bolts on both sides of the suspension.
12. Lower the floor jack and pivot the cross tube and support beam ‘U’ assembly down.
13. Remove the QUIK-ALIGN bolts, washers, locknuts, and collars.
14. Remove both support beams from the hangers.
15. Remove the support beams and cross tube as an assembly from the vehicle.
16. Remove the end cap on the support beam(s) being removed from the cross tube.
17. Dislodge the support beam from the cross tube by hitting the support beam directly in
front of the inboard corner joint.
18. The support beam and cross tube joint requires shock load on the support beam at the
joint to dislodge the two components. All blunt force must be applied flush to the
thickest part of the support beam at the inboard corner joint. Continue striking the
support beam until it is completely dislodged from the cross tube. Inspect all
components for any damage or wear and replace as necessary.

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PRIMAAX® Gen II Maintenance

ASSEMBLY

1. Clean the cross tube exterior from any rust or debris using a wire wheel. When
installing a new cross tube, ensure all preservative is removed prior to installation.
2. Clean the bore on the support beam assembly that accommodates the cross tube to
remove corrosion or preservatives.
3. Clean the QUIK-ALIGN slots in the hangers from any dirt and debris.
4. Clean the QUIK-ALIGN collars of any dirt and debris and inspect for any wear or
damage. Replace as necessary.
5. Place both beams and cross tube on the floor for preassembly.
6. Install the cross tube into the support beams one side at a time.
7. Install and tighten the end caps to the specified torque value.
8. Position the support beam and cross tube as an assembly on a floor jack.
9. Raise the support beam and cross tube as an assembly until the D-pins engage in the
bottom cap.
10. Install the D-pin fasteners.
11. Install the support beams and cross tube as an assembly into the hangers. Apply
lubricant to the pivot bush rubbers to allow easy fitment into the hangers.
12. Install QUIK-ALIGN connection with new Dacromet fasteners and tighten to the
specified torque value.
13. Tighten D-Pin locknuts to the specified torque value.
14. Attach the air springs to the cross tube.
15. Install the wheels.
16. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication
prior to inflating the suspension system.
17. Connect the levelling valve link rod to the height control valve arm(s) to Inflate the
suspension.
18. Alignment is necessary anytime the support beam is removed.

WARRANTY PRESERVATIVE MUST BE REMOVED FROM ALL NEW BEAMS AND CROSSTUBES
PRIOR TO ASSEMBLY. FAILURE TO DO SO WILL PREVENT CORRECT CLAMPING
FORCE AT THE CONNECTION WHICH WILL LEAD TO PREMATURE COMPONENT
FAILURE AND MAY RESULT IN PERSONAL INJURY OR LOSS OF VEHICLE
CONTROL.

NOTE: THE WEIGHT OF THE SUPPORT BEAMS AND CROSS TUBE ASSEMBLY IS
APPROXIMATELY 100 kgs. CARE SHOULD BE TAKEN AT REMOVAL AND
INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS.

NOTE: DO NOT STRIKE SUSPENSION COMPONENTS WITH A HAMMER. HOWEVER, THE

SUPPORT BEAM AND CROSS TUBE JOINT REQUIRES BLUNT FORCE ON THE
SUPPORT BEAM AT THE JOINT TO DISLODGE THE TWO COMPONENTS. ALL
BLUNT FORCE MUST BE APPLIED FLUSH TO THE THICKEST PART OF THE
SUPPORT BEAM AT THE INBOARD CORNER JOINT, FAILURE TO STRIKE THE
SUPPORT BEAM SQUARELY MAY RESULT IN COMPONENT DAMAGE, PREMATURE
FAILURE AND VOID WARRANTY.

NOTE: IT MAY BE NECESSARY TO USE A PRY BAR TO DISENGAGE THE D-PINS FROM
THE BOTTOM CAPS. IT ALSO MAY BE NECESSARY TO USE A PRY BAR TO PUSH
THE SUPPORT BEAMS OUT OF THE FRAME HANGERS.

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PRIMAAX® Gen II Maintenance

SERVICE HINT: When support beam removal is required it is necessary to remove both support
beams and the cross tube as an assembly.

SERVICE HINT: It may be necessary to raise the front of the differential to allow the D-pins to engage
in the bottom cap. Use a drift pin if necessary, to align the D-pins with the bottom
cap.

SERVICE HINT: It may be necessary to rotate the QUIK-ALIGN eccentric collars to pull the axle
forward to allow the full engagement of the D-pins into the bottom caps.

D-Pin Bush
Special tools required: a vertical shop press with a capacity of at least 10 tons. A D-Pin
Removal Tool, Installation Tool, and Receiving Tool.

DISMANTLING
1. Remove the support beam assembly. Follow support beam removal procedure in the
Component Replacement Section of this publication.
2. Place the support beam in a shop press on top of the receiving tool with both ends of
the support beam supported squarely on the press bed.
3. Mark the clocking position of the D-pin bush on the support beam with a paint stick.
4. Install the D-Pin Removal Tool squarely centred on the D-Pin bush.
5. Push directly on the D-pin Removal Tool until the D-Pin bush is pressed out of the
support beam bore.
6. 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.

ASSEMBLY
1. Place the support beam in a shop press on the receiving tool with the bevelled 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 bush retaining sleeve with
chassis grease.
3. Line up the D-pin bush with the clocking line that was put on the support beam prior to
the removal of the D-pin bush.
4. Install the D-pin bush installation tool and press in the new D-pin bush until the
confinement sleeve protrudes equally on both sides of the support beam assembly.
5. Install the support beam assembly.
6. Follow support beam installation procedure in the Component Replacement Section of
this publication.

Quick-align Pivot Bush

DISMANTLING
Special tools required: A vertical shop press with a capacity of at least 10 tons. A 6" long
piece of 4" inner diameter by 1/4" wall steel tubing receiving tool is required.
1. Remove the support beam assembly. Follow the support beam removal procedure in
the Component Replacement Section of this publication.
2. Place the support beam in a shop press.
3. Support the support beam on the receiving tool with the beam eye centred on the
receiving tool. Be sure the support beam is squarely supported on the press bed.
4. Centre the push out tool on the inner sleeve and press out the old bush, (these bushes
are not cartridge type bushes, they do not have outer metals).
5. Clean and inspect the inside diameter of the support beam eye.

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PRIMAAX® Gen II Maintenance

ASSEMBLY
1. Lubricate the inner diameter of the support beam eye with a suitable lubricant, such as
P-80 (Hendrickson part number 70867-001). DO NOT use petroleum or soap base
lubricant, it can cause an adverse reaction with the bush material, such as
deterioration.
2. Support the support beam on the receiving tool with the beam eye centred on the tool.
Be sure the support beam is squarely supported on the press bed.
3. Place the QUIK-ALIGN bush installer tool (Refer to the 97114-070 parts list for all
special tools available) on the QUIK-ALIGN bush.
4. Press in the new bush. Bushes must be centred within the support beam eye. When
pressing in the new bushes over-shoot desired final position by 3/16" and press again
from the opposite side to centre the bush within the support beam eye
bore, if necessary.
5. Install the support beam assembly.
6. Follow support beam installation procedure in the Component Replacement Section of
this publication.

Top Pad
Top Pad

DISMANTLING
1. Chock the front wheels.
2. Support the frame.
3. Disconnect the levelling valve arm from the control rod. See Air Spring Cautions and
Warnings in the Safety Notice Section of this publication prior to deflating or deflating
the suspension system.
4. Lower the levelling valve arm to exhaust the air in the air springs and deflate the rear
suspension.
5. Remove the through bolt from the longitudinal torque rod to access the U bolt
locknuts.
6. Support the support beam assembly. Remove the U bolts from the clamp group.
Remove the top pad.
7. Inspect the top pad and the axle housing for any cracks, elongation of the mounting
holes or damage. Replace if necessary.

SERVICE HINT: Due to certain pinion angle configuration the removal of the D-pin bolts may be
necessary

ASSEMBLY
1. Install the top pad on the top of the axle engaging the dowel pin.
2. Install new U bolts, washers, and locknuts.
3. Verify that the U bolts are seated properly in the channels of the top pad.
4. Tighten the U bolt locknuts evenly and tighten to the correct torque in the correct
sequence.
5. Rap the top of the U bolts with a dead blow mallet and retighten to the correct torque.

DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS.

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PRIMAAX® Gen II Maintenance

6. Tighten the 3/4” locknuts to the specified torque value.

7. Tighten the 3/4” D-pin bolts to the specified torque setting if loosened or removed
during dismantling.
8. Remove the floor jack or bottle jack from the support beam assembly.
9. Install the through bolt on the longitudinal torque rod,
10. DO NOT tighten at this time. See Air Spring Cautions and Warnings in the Safety
Notice Section of this publication prior to inflating the suspension system.
11. Connect the levelling valve link rod to the height control valve arm to inflate the
suspension.
12. Remove the frame stands.
13. Tighten the longitudinal torque rod through bolt to the specified torque setting.
14. Remove the wheel chocks.

NOTE: Prior to tightening the longitudinal torque rod through bolt Locknut to torque
specifications, it is mandatory that the vehicle is at the proper ride height.

Bottom Cap

Bottom Cap

DISMANTLING
1. Chock the wheels of the axle.
2. Raise the frame of the vehicle to remove the load from the suspension.
3. Support the frame. Remove tyres if necessary.
4. Support the axle.
5. Disconnect the levelling valve arm from the Link Rod.
6. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication
prior to deflating or deflating the suspension system.
7. Lower the levelling valve arm to exhaust the air in the air springs and deflate the rear
suspension.
8. Remove the lower shock absorber mounting fasteners.
9. Remove the S-cam support bracket fasteners and support bracket (if equipped).
10. Support the support beams and cross tube assembly with a floor jack that equipped
with a four inch support plate.
11. Remove the D-pin fasteners.
12. Raise the front of the differential to facilitate removal of the D-pins from the bottom
caps.
13. Lubricate the lower mounting fasteners with penetrating oil and remove with hand
tools from the air spring mounting studs.
14. Remove both the lower air spring mounting brackets to disconnect both air springs
from the cross tube.
15. Loosen the QUIK-ALIGN bolts but do not remove QUIK-ALIGN mounting hardware.
16. Pivot the support beams and cross tube assembly down from the bottom caps.
17. Remove the U bolt locknuts and washers.
18. Remove the bottom cap and inspect for damage or wear. Replace as necessary.

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PRIMAAX® Gen II Maintenance

NOTE : THE USE OF A FLOOR JACK EQUIPPED WITH A 100 mm SUPPORT PLATE IS
MANDATORY TO SUPPORT THE SUPPORT BEAM AND CROSS TUBE 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 ASSEMBLY.
FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE OR RESULT IN PERSONAL
INJURY.

NOTE: THE WEIGHT OF THE SUPPORT BEAMS AND CROSS TUBE ASSEMBLY IS
APPROXIMATELY 100 kg.
CARE SHOULD BE TAKEN AT REMOVAL AND INSTALLATION TO PREVENT
PERSONAL INJURY OR DAMAGE TO COMPONENTS.

SERVICE HINT: Mark the position of the QUIK-ALIGN square drive in relationship to the frame
hanger with a paint stick prior to loosening the QUIK-ALIGN connection. This will
facilitate the axle alignment process after the repair is complete.

SERVICE HINT: It may be necessary to rotate the QUIK-ALIGN eccentric collars to the full rearward
position to facilitate the removal and installation of the D-pins into the bottom caps.

ASSEMBLY
1. Install the new U bolts.
2. Install the bottom axle cap in the axle in the proper direction, with the lower shock
mounting holes facing the rear of the vehicle.
3. Attach the 3/4” washers and the locknuts.
4. Align the clamp group; verify that the top pad is indexed properly on the dowel located
on the top of the axle beam.
5. Verify that the U bolts are seated properly in the channels of the top pad.
6. Tighten the U bolt locknuts evenly and tighten to the proper torque in
the proper sequence. 3/4”
7. Rap the top of the U bolts with a dead blow mallet and retighten to the proper
torque. DO NOT EXCEED SPECIFIED TORQUE ON U BOLT LOCKNUTS.
8. Tighten the 3/4” locknuts to the specified torque settings.
9. Install the lower shock absorber mounting fasteners.
10. Tighten the 5/8" locknuts the specified torque settings.
11. Install the S-Cam support bracket and fasteners (if equipped).
12. Tighten the 3/8" locknuts and the 5/16" locknuts to the specified torque settings.
13. Raise the support beam and cross tube assembly until the D-pins engage in the
bottom cap.
14. Install the D-pin fasteners and install from front to back.
15. Lower the bottle jack from the front of the differential to allow the full
engagement of the D-pins into the bottom caps.
16. Tighten the D-Pin 3/4” locknuts to the specified torque settings.
17. Attach the air springs to the cross tube.
18. Install the Tyres (if removed).
19. Remove the jack stands and lower the frame of vehicle.
20. See Air Spring Cautions and Warnings in the Safety Notice Section of this publication
prior to deflating or inflating the suspension system.
21. Connect the levelling valve link rod to the height control valve arm to Inflate
the suspension.
22. Alignment is necessary anytime the support beam is removed to complete
the repair. See Alignment Section of this publication.

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PRIMAAX® Gen II Maintenance

SERVICE HINT: It may be necessary to squeeze the U bolts slightly to facilitate installation through
the bottom axle cap.
SERVICE HINT: It may be necessary to rotate the QUIK-ALIGN eccentric collars to pull the axle
forward to allow the full engagement of the D-pins into the bottom caps.

SERVICE HINT: It may be necessary to raise the front of the differential to allow the D-pins to engage
the bottom cap.

Axle Bump Stops

DISMANTLING
1. Chock the wheels.
2. Remove the fasteners connecting the axle bump stop to the frame.
3. Remove the axle stop.
4. Inspect the frame rail mounting surfaces for any cracks or damage.

ASSEMBLY
1. Install the axle bump stop on the frame.
2. Install new mounting fasteners.
3. Tighten axle stop fasteners to the vehicle manufacturers torque specifications.
4. Install any items removed
5. Remove the wheel chocks.

Frame Hanger

Replacement of the hanger is required when the frame hanger has been damaged or worn.

THE PROCEDURE TO REPLACE A FRAME HANGER, IS DONE WITH THE

REMAINING FRAME HANGERS CONNECTED TO THE FRAME AND IT IS ALSO
NECESSARY THAT THE SUPPORT BEAMS AND THE LONGITUDINAL TORQUE
RODS ARE ATTACHED TO THE THREE REMAINING FRAME HANGERS.

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DISMANTLING
1. Chock the front wheels.
2. Support the frame
3. Disconnect the levelling valve arm from Control Rod.
4. Lower the levelling valve arm to exhaust the air in the air springs and deflate the rear
suspension.
4. Remove the QUIK-ALIGN lock nut and pivot bolt and discard.
5. Remove the QUIK-ALIGN collars that connect the support beam to the frame hanger.
6. Remove the fasteners that attach the longitudinal torque rod to the frame hanger.
7. Remove the fasteners that attach the frame hanger to the vehicle per vehicle
manufacturer specifications.
8. Remove the frame hanger.
9. Inspect mounting surface for any damage or wear.
10. Inspect the QUIK-ALIGN pivot washers, bush and torque rod bushes for wear or
damage, replace as necessary.

ASSEMBLY
1. Slide the new frame hanger over the support beam QUIK-ALIGN bush.
2. Install the new fasteners from hanger to frame rail and tighten per vehicle manufacturer
specifications.
3. Install the new QUIK-ALIGN collars and the new mounting hardware that attach the
support beam to the frame hanger
4. Verify that the nose of each QUIK-ALIGN collar is installed correctly into pivot bush
sleeve, and the flanged side is flat against the frame hanger face within the alignment
guides.
5. Attach the new QUIK-ALIGN mounting hardware.
6. Install the torque rod mounting 3/4” fasteners.
7. Connect the levelling valve link rod(s) to the height control valve arm(s) to Inflate the
suspension properly.
8. Verify that the axle is in proper alignment. See Alignment Section in this publication.
9. After the correct alignment of the axle is verified tighten the 1" QUIK-ALIGN locknuts to
the specified torque settings.
10. Tighten the longitudinal 3/4” mounting fasteners to specified torque settings.
11. Verify the correct pinion angle on the axle per original equipment manufacturers
specifications.
12. Remove the chocks from the front wheels.
SERVICE HINT: Be aware of the quantity of shims removed to maintain the correct pinion angle of
the axle at assembly. See Alignment Section in this publication.
NOTE: Use a new support beam QUIK-ALIGN Bolt Kit (refer to the 97114-070 Parts List) for
any axle alignment or Dismantling 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.

NOTE: Prior to tightening the QUIK-ALIGN locknuts to torque specifications, it is

mandatory that the vehicle is at the proper ride height.

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SECTION 7 Plumbing Diagram

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SECTION 8 Torque Specifications

PRIMAAX RECOMMENDED TORQUE SPECIFICATIONS

NO COMPONENT QTY SIZE TORQUE Nm
(ft/lb)
1 Frame Hanger ** 16 3/4” - 10 UNC 505 (375)
A. To Forward Hanger Mount 4 3/4” – 16 UNF 400 (300)
2 Longitudinal Torque
Rod B. To Rear Top Pad Mount 2 7/8” – 14 UNF 750 (550)
C. To Rear Top Pad Mount 2 M24 980 (725)
A. QUIK-ALIGN **** 2 1” – 14 UNF 750 (550)
3 Beam Assembly A. QUIK-ALIGN 2 1 – 8 UNC 850 (625)
B. QUIK-ALIGN – Extreme Duty 2 1”1/4 – 12 UNF 1,760 (1,300)
C. Centre D-Pin Bush 2 3/4” – 16 UNF 400 (300)
D. Cross Tube End Cap 2 7/8” – 9 UNC 750 (550)
4 U Bolt Locknuts 8 3/4” – 16 UNF 440 (325)
A. Upper Mount Locknuts 2 3/4” – 10 UNC 250 (185)
5 Shock Absorber
B. Lower Mount Locknuts 2 5/8” –11 UNC 285 (210)
6 Upper Shock Absorber Bracket to Frame ** 4 5/8” – 11 UNC 285 (210)
A. To Frame ** 2 5/8” – 11 UNC 285 (210)
7 Air Spring Assembly
B. Lower to Cross Tube 4 1/2” – 13 UNC 35 (25)
8 Axle Stop to Frame ** 6 5/8” – 11 UNC 285 (210)
9 Height Control Valve to Frame Bracket 2 1/4” – 20 UNC 15 (10)
A. Jam Nut 2 5/16”– 18 UNC 15 (10)
10 HCV Linkage
B. Locknut to HCV 2 5/16”–18 UNC 15 (10)
C. Clamp 1 Until Securely
Fastened

NOTE * Quantities shown are per axle except for items 9 & 10.
** Denotes items not shown on the illustration
*** All Hardware should be checked for correct tension at Assembly, Pre-Delivery,
First Service and thereafter at 50,000 km intervals
**** Introduction of 1”-14 UNF QUIK-ALIGN bolt Oct 2010 thread & torque change

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SECTION 9 Trouble Shooting Guide

PRIMAAX TROUBLESHOOTING GUIDE

CONDITION POSSIBLE CAUSE CORRECTION
Air spring not inflated to specification or
Repair air system and check ride height.
damaged
Suspension has harsh or
Ride Height Set Incorrectly Adjust ride height to proper setting.
bumpy ride
Suspension is overloaded Redistribute load to correct weight.
Broken support beam Replace broken support beam assembly.
Correct Tyre pressure per vehicle manufacturer
Incorrect tyre inflation pressure
and tyre manufacturer specifications.
Worn QUIK-ALIGN bush Replace QUIK-ALIGN bush.
Irregular Tyre Wear Replace QUIK-ALIGN connection, and check
vehicle alignment, Adjust if necessary, Check
Loose QUIK-ALIGN attachment
frame hanger for wear around QUIK-ALIGN
plates and replace if necessary.
Worn Torque rod bushes Replace Torque rod bushes
Adjust pinion angle(s), refer to vehicle
Incorrect pinion angle(s) manufacturer for specifications.
Ride Height Set Incorrectly Adjust ride height to proper setting.
Excessive driveline vibration
Broken support beam Replace broken support beam assembly
Air spring not inflated to specification or
Repair air system and check ride height.
damaged
Damaged or leaking shock absorber Replace shock absorber.
Excessive vehicle bouncing
Ride height set incorrectly Adjust ride height to proper setting.
Replace QUIK-ALIGN connection, and check
Loose QUIK-ALIGN attachment
vehicle alignment.
Loose U Bolts Tighten U Bolts to specification.
Suspension noisy
Inspect end caps and support beam to cross
Loose end caps
tube connection & repairs as necessary.
Worn Torque Rod bushes Replace Torque rod bushes.
Air spring not inflated to specification or
Repair air system and check ride height
damaged.
Load not centred Redistribute the load.
Straighten frame as per manufacturers
Vehicle leaning Frame Twisted
specifications.
Broken support beam Replace broken support beam assembly.
Loose U Bolts Tighten U Bolts to specification.
Front Suspension Inspect and repair front suspension.

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Amendment Table
Date Revision Page Notes
Nov-2010 Rev O Page 1 Header Layout and Revision to O
Nov-2010 Rev O Page 32 Add 1”-14 UNF Quick Align Torque 750 Nm
Mar-2020 Rev P All Remove parts & tools sections. Revise document, ECN 11679.

Actual product performance may vary depending upon vehicle configuration, operation, service and other factors.
All applications must comply with applicable Hendrickson specifications and must be approved by the respective vehicle manufacturer with the vehicle in its original, as-built configuration.
Contact Hendrickson for additional details regarding specifications, applications, capacities, and operation, service and maintenance instructions.

HENDRICKSON
ABN 21 004 992 769
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. © 2003 – 2020 Hendrickson USA, L.L.C. All Rights Reserved.
32-34 Letcon Drive/P.O. Box 1063,
Dandenong South, Victoria 3175 Australia
Phone 61.3.9767.3600 Fax 61.3.8792 3699
www.hendrickson.com.au All trademarks shown are owned by Hendrickson USA, L.L.C., or one of its affiliates, in one or more countries.

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