[H]TECBNICAL
®PROCEDURE
PRIMAAX® EX I PRIMAAX® for
Volvo Vehicles
SUBJECT: Service Instructions
LIT NO: 17730-254
DATE: April 2013
REVISION: D

IM:J11.1u.1011t•ti
Section 1

Introduction ........................ 2

Section 2

Product Description ................. 2

Section 3

Important Safety Notice .............. 4

Section 4

Special Tools ....................... 9

Section 5

Parts Lists . ........................ 12

Section 6

Preventive Maintenance . ............ 16
Areas of Inspection ................... 16
Hendrickson Recommended Preventive
Maintenance Intervals .............. 16
Component Inspection ................ 18
U-bolt Fasteners ..................... 19
Pivot Bushing and D-Pin Bushing Inspection 20
Transverse Torque Rods ................ 22
Longitudinal Torque Rods .............. 22
Shock Absorber ...................... 23
Air Fitting Inspection .................. 24

Section 7

Section 8

Component Replacement ........... 31
Fasteners .......................... 31
Height Control Valve .................. 31
Air Spring .......................... 31
ShockAbsorber ...................... 33
Transverse Torque Rod ................. 33
Longitudinal Torque Rod ............... 34
Longitudinal Torque Rod Bushing ......... 35
Support Beam Assembly and Cross Tube ... 36
U-beam Assembly .................... 37
D-pin Bushing ....................... 40
QUIK-ALIGN Pivot Bushing .............. 45
Top Pad ............................ 46
Bottom Cap and Axle Spacer ............ 48
Axle Stops .......................... 51
Frame Hanger ...................... 52

Section 9

Torque Specifications ............... 54

Section l O Troubleshooting Guide . ............. 58

Alignment & Adjustments ........... 25
Ride Height Adjustment ................ 25
Lateral Alignment .................... 25
Axle Pinion Angle .................... 26
Drive Axle Alignment Inspection Procedure . 26
Alignment Adjustment Instructions ....... 28
Pinion Angle Adjustment ............... 30

~HENDRICKSON
~R/~H~R:msOhUs®

PRIMAAX® EX I PRIMAAX® for Volvo Vehicles

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SECTION 1

Introduction
This publication is intended to acquaint and assist maintenance personnel in the preventive
maintenance, service, repair and rebuild of the PRIMAAX® EX/ PRIMAAX® suspension systems as
installed on applicable Volvo Vehicles.
NOTE

Use only Genuine HHendrickson parts for servicing this suspension system.
It is important to read and understand the entire Technical Procedure publication prior to performing any maintenance, service, repair, or rebuild of this product. The information in this
publication contains parts lists, safety information, product specifications, features, proper maintenance, service, repair and rebuild instructions for the PRIMAAX EX I PRIMAAX Suspensions for
Volvo vehicles.
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 version of this manual at 1-866-755-5968 (toll-free U.S. and Canada), 630-910-2800 (outside U.S.
and Canada) or e-mail: techservices@hendrickson-intl.com.
The latest revision of this publication is also available on line at
www.hendrickson-intl.com

SECTION 2

Product Description
PRIMAAX EX - MAAXimize the performance of vocational and heavy-haul vehicles with a
suspension engineered specifically for demanding on- and off- road conditions including, but
not limited to: truck, tractor, dump, front and rear discharge mixer, crane, refuse, drilling rig, logging, platform, specialty and vehicles equipped with outriggers*. With more than 95 years of
robust suspension design, Hendrickson delivers another premium suspension with PRIMAAX EX.
Rugged, dependable and extensively tested in challenging applications, PRIMAAX EX paves a
new road for suspension technology.

U.S. and foreign patents granted and/or pending.
Introduction

2

17730-254

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PRIMAAX® EX I PRIMAAX® for Volvo Vehicles
•
•
•
•
•
•

Air springs - Large volume. low frequency design for premium ride quality. Advanced
design air springs lift and support the load with less air pressure.
Axle connections - D-pin axle connection decreases torsional axle stress for reduced maintenance and increased joint integrity. Integrated axle stop contact pads reduce axle stress.
Genuine Hendrickson torque rods - Optimized configuration helps improve handling and
roll stiffness for expanded applications.
Heavy-duty shock absorbers - Positioned and tuned for optimum damping characteristics.
QUIK-ALIGN® -Allows for easy axle alignment without shims. Reduces maintenance time
and helps extend tire life.
Structural beams I cross beams - Cast structural beams form a solid connection with
the square cross brace to form a rigid torsion and stabilizer system. Redesigned structural
beams utilize premium materials and are proven in some of the most challenging environments. Integrated beam end cap allows for a maintenance-free connection with the cross
beam for increased uptime. Robust rubber bushings improve service life and eliminate
lubrication requirements.

PRIMAAX® EX SPECIFICATIONS FOR VOLVO VEHICLES
Capacity
Axle Configuration
Site Travel Rating 1
Axle Travel2
Ground Clearance
Lift Axles
Ride Heights3
Engine Torque Restrictions
Axle Spacing

46,000 lbs.
Tandem
60,000 lbs.
7.0", 7.5"
9.25"
Approved
8.5"
None
52"- 72.5"

69,000 lbs.
Tridem
90,000 lbs.
7.0", 7.5"
9.25"
Approved
8.5"
None
108"

l. Operators using vehicles equipped with liftable push or tag axles must not exceed published ratings. Ratings are
limited to no more than five percent of vehicle operation at a speed not to exceed five mph. Liftable pusher or tag
axles should be raised (or unloaded) to improve vehicle maneuverability in off-road use or when vehicle is empty.
Site travel ratings are consistent with specifications and must not be exceeded.
2. Axle travel may be limited by vehicle manufacturer; axle stop settings may restrict suspension's articulation.
3. For different ride height options, please contact Hendrickson, your vehicle manufacturer or authorized vehicle
dealer for further information.

• Some vehicle configurations, such as vehicles equipped with outriggers, may require alternate suspension air valving. Contact vehicle manufacturer or
Hendrickson for more information.
17730-254

3

Product Description

PRIMAAX® EX I PRIMAAX® for Volvo Vehicles

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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 damage
the vehicle, cause personal injury, render the vehicle unsafe in operation, 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 all such materials 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
minimize the risk of personal injury to service personnel, or possibility of improper service methods 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.

m

The following definitions indicate the use of these signal words as they appear throughout the
publication.

A

DANGER

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
SERIOUS INJURY OR DEATH.

A

WARNING

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, CAN RESULT IN SERIOUS
INJURY OR DEATH.

A

CAUTION

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR
MODERATE INJURY, OR PROPERTY DAMAGE.

NOTE

An operating procedure, practice condition, etc. which is essential to emphasize.

SERVICE HINT

A helpful suggestion, which will make the servicing being performed a little easier and/or faster.
Also note that particular service operations may require the use of special tools designed
for specific purposes. These special tools can be found in the Special Tools Section of this
publication.
The torque symbol alerts you to tighten fasteners to a specified torque value. Refer to Torque
Specifications Section of this publication.

Important Safety Notice

4

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PRIMAAX® EX I PRIMAAX® for Volvo Vehicles
• SAFETY PRECAUTIONS

A

WARNING

FASTENERS
DISCARD USED FASTENERS. ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR. FAILURE TO
DO SO COULD RESULT IN FAILURE OF THE PART OR MATING PARTS, LOSS OF VEHICLE CONTROL,
PERSONAL INJURY, OR PROPERTY DAMAGE.
LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, LOSS OF VEHICLE
CONTROL, PROPERTY DAMAGE, OR SEVERE PERSONAL INJURY. MAINTAIN CORRECT TORQUE
VALUE AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED, USING A
TORQUE WRENCH THAT IS REGULARLY CALIBRATED. TORQUE VALUES SPECIFIED IN THIS TECHNICAL
PUBLICATION ARE FOR HENDRICKSON SUPPLIED FASTENERS ONLY. IF NON HENDRICKSON
FASTENERS ARE USED, FOLLOW TORQUE SPECIFICATION LISTED IN THE VEHICLE MANUFACTURER'S
SERVICE MANUAL.

A

WARNING

QUIK-ALIGN FASTENERS
DISCARD USED QUIK-ALIGN FASTENERS. ALWAYS USE NEW QUIK-ALIGN FASTENERS TO COMPLETE A
REPAIR. FAILURE TO DO SO COULD RESULT IN FAILURE OF THE PART, OR MATING COMPONENTS, LOSS
OF VEHICLE CONTROL, PERSONAL INJURY, OR PROPERTY DAMAGE.
DO NOT ASSEMBLE QUIK-ALIGN JOINT WITHOUT THE PROPER FASTENERS. USE ONLY H-COATED
FASTENERS 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 IN THE TORQUE
SPECIFICATIONS SECTION OF THIS PUBLICATION. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE
CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.

A

WARNING

A

WARNING

MODIFYING COMPONENTS
DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON. DO NOT
SUBSTITUTE REPLACEMENT COMPONENTS NOT AUTHORIZED BY HENDRICKSON. USE OF MODIFIED,
REWORKED, SUBSTITUTE OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY
NOT MEET HENDRICKSON'S SPECIFICATIONS, AND CAN RESULT IN FAILURE OF THE PART, LOSS
OF VEHICLE CONTROL, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE, AND WILL VOID
WARRANTY. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.

A

WARNING

TORCH/WELDING
DO NOT USE A CUTTING TORCH TO REMOVE ANY FASTENERS. THE USE OF HEAT ON SUSPENSION
COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS. A COMPONENT
DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS OF VEHICLE CONTROL AND POSSIBLE
PERSONAL INJURY OR PROPERTY DAMAGE.

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.

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. DO NOT USE HEAT NEAR
THE U-BEAM ASSEMBLY. DO NOT NICK OR GOUGE THE SUPPORT BEAM. SUCH IMPROPER ACTIONS
CAN DAMAGE THE U-BEAM ASSEMBLY AND CAUSE LOSS OF VEHICLE CONTROL AND POSSIBLE
PERSONAL INJURY OR PROPERTY DAMAGE.

17730-254

5

Important Safety Notice

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PRIMAAX® EX I PRIMAAX® for Volvo Vehicles

A

WARNING

CROSS TUBE, SUPPORT BEAM AND U-BEAM ASSEMBLY
FIGURE 3-1

WHEN SEPARATING THE U-BEAM ASSEMBLY, PROTECT THE
CROSS TUBE BY PLACING A PIECE OF PLYWOOD 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
Do not strike the
FRONT OF THE INBOARD TOP CORNER JOINT. ALL BLUNT
Support Beam Flanges
FORCE MUST BE APPLIED FLUSH TO THE THICKEST PART
OF THE SUPPORT BEAM. FAILURE TO STRIKE THE SUPPORT BEAM SQUARELY MAY RESULT IN
COMPONENT DAMAGE, PREMATURE FAILURE AND VOID WARRANTY, SEE FIGURE 3-1.

A

WARNING

CROSS TUBE
IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE (SEE SAFETY DECAL, FIGURE
3-2) AND RESULT IN LOSS OF VEHICLE CONTROL, SEVERE PERSONAL INJURY OR DEATH AND WILL
VOID HENDRICKSON'S WARRANTY.
FIGURE 3-2

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UNAUTHORIZED WELDING OR MODIFICATIONS can cause
structural damage and result In IOBB of vehicle control, severe personal Injury or
death. Do not bend, weld or modify cross brace without authorization from
Hendrickson Truck Suspension Systems.
IMPROPER JACKING METHOD can cause sllUctural damage and result In
loss ot vehicle control, severe personal Injury or death.
• Do not use suspension cross brace as aJacking: point.
• Refer to vehicle manufacturer for proper Jacking: lnstruetlons.
NO. 6090 5-015 A