Hendrickson ULTIMAAX 58K Referenzhandbuch

ULTIMAAX®Rear Suspension

for Fire and Rescue Vehicles

SUBJECT: Service Instructions

LIT NO: 17730-299

DATE: July 2018 REVISION: B

TABLE OF CONTENTS

Section 1 Introduction ........................2

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

Section 3 Important Safety Notice ..............4

Section 4 Special Tools .......................8

Section 5 Parts List..........................10

Section 6 Preventive Maintenance

Hendrickson Recommended

Inspection Intervals ................13

Component Inspection ................13

Center Bushings .....................14

Equalizing Beam End Connection ........15

Bar Pin End Bushings .................18

Bar Pin Shims .......................18

Beam End Axle Brackets ...............19

Frame Hanger Assembly ...............20

Shear springs .......................20

Progressive Load Springs (PLS) ..........21

Saddle Connection ...................22

Cross Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Torque Rods ........................24

Shock Absorbers .....................25

Section 7 Alignment & Adjustments

Drive Axle Pinion Angle ................27

Drive Axle Alignment ..................27

Axle Lateral Alignment.................29

Bar Pin Alignment ....................29

Section 8 Component Replacement

Fasteners ..........................32

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

Shear Spring / Frame Hanger Assembly /

Saddle Assembly ..................33

Progressive Load Spring (PLS)...........38

Equalizing Beam.....................38

Equalizing Beam Center Bushing.........41

Bar Pin Style End Bushings .............44

Adapter Style End Bushings.............46

Cross Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 50

Torque Rods ........................51

Torque Rod Bushings..................52

Section 9 Troubleshooting Guide ..............57

Section 10 Torque Specications ...............58

217730-299

ULTIMAAX®for Fire and Rescue Vehicles

SECTION 1

Introduction

This publication is intended to acquaint and assist maintenance personnel in the preventive

maintenance,service,and repair of the ULTIMAAX®Rear Rubber Suspension System for applicable

Fire and Rescue Vehicles.

NOTE Use only Hendrickson Genuine parts for servicing this suspension system.

It is important to read and understand the entire Technical Procedure publication prior to

performing any maintenance, service, or repair of this product.The information in this publica-

tion contains parts lists, safety information, product specifications, features, proper maintenance,

service, and repair instructions for ULTIMAAX suspensions.

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),1-630-910-2800 (outside U.S.and

Canada) or e-mail: [email protected].

The latest revision of this publication is available online at www.hendrickson-intl.com.

SECTION 2

Product Description

ULTIMAAX is an advanced severe-duty rear rubber suspension designed specifically for fire and

rescue applications to balance outstanding durability, empty ride quality, loaded stability and

mobility.Through its unique design, the system offers premium ride quality in both empty and

loaded conditions,with increasing stability as the load increases.

■ Equalizing beam — Formed and robotically welded to provide a narrow profile for weight

savings. Distributes load equally between axles to improve maneuverability, stability and

handling.Increases ground clearance with flat bottom design. Lowers the center of gravity to

increase stability.

■ Saddle — Triangular geometry provides structure and durability. Weight efficient design

helps to increase payload, while offering a considerable weight savings versus competitive

suspensions.

■ Frame hangers — Optimized design to balance durability and weight savings.Fabricated to

offer flexibility with multiple truck configurations.

■ Rubber shear springs — Primary springs in unloaded condition,providing superb ride quality.

React to longitudinal loads during braking and accelerating for minimal displacement.

■ Progressive load springs — Designed to balance empty ride quality and loaded stability.

Stiffness of progressive load spring increases as load increases,providing a unique balance

of empty ride quality and loaded stability.

■ Longitudinal torque rods — Engineered to optimize resistance to axle wind-up during accel-

eration and braking.

■ Transverse torque rods — Heavy-duty transverse torque rods ensure maximum lateral axle

control and straight line suspension stability.

17730-299 3

ULTIMAAX®for Fire and Rescue Vehicles

FIGURE 2-1

54K•58K Capacity

9½"•10"•10¼"•11½" Ride Height

63K Capacity

10"•10½" Ride Height

ULTIMAAX®SPECIFICATIONS

54K 58K 63K

Suspension Rating 54,000 lbs (24,494 kg) 58,000 lbs (26,308 kg) 63,000 lbs (28,576 kg)

Diagonal Articulation117½" (445 mm)

Ride Heights 9½"•10"•10¼"•11½" (241 mm,254 mm,260 mm,292 mm) 10", 10½" (254 mm, 267 mm)

Axle Spacing254" (1,372 mm) 54", 56" (1,372 mm, 1,422, mm)

Hendrickson approves the use of ULTIMAAX in fire / rescue applications. All such applications must comply with applicable Hendrickson

specifications and must also be approved by the respective vehicle manufacturer with the vehicle in its original, as-built configuration.

Contact Hendrickson and the respective vehicle manufacturer for approval of additional applications.

1. Suspension articulation may exceed vehicle’s capability and may be limited by vehicle manufacturer; vehicle manufacturer installed axle

stops may restrict suspension’s articulation.

2. Contact Hendrickson for availability of additional beam lengths.

For additional details regarding specifications, applications, capacities, operating service and maintenance instructions, refer to applicable

Hendrickson technical literature (available at www.hendrickson-intl.com) or contact Hendrickson at 1-866-768-5968.

Actual product performance may vary depending upon vehicle configuration, operation, service and other factors.

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

417730-299

ULTIMAAX®for Fire and Rescue Vehicles

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.

This technical publication 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 the 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 in 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 mini-

mize 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 haz-

ards.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 impor-

tance and provide suggestions for ease of repair.The following definitions indicate the use of

these signal words as they appear throughout the publication.

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,WHICH IF NOT AVOIDED,WILL RESULT IN SERIOUS

INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, CAN RESULT IN SERIOUS

INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR

MODERATE INJURY.

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

SERVICE HINT A helpful suggestion that 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 the fasteners to a specific torque value. See Torque

Specifications Section of this publication.

17730-299 5

ULTIMAAX®for Fire and Rescue Vehicles

■ SAFETY PRECAUTIONS

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 COMPONENTS,ADVERSE VEHICLE HANDLING,

PERSONAL INJURY,OR PROPERTY DAMAGE.

LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, ADVERSE VEHICLE

HANDLING, PROPERTY DAMAGE,OR SEVERE PERSONAL INJURY. MAINTAIN CORRECT TORQUE VALUE

AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED, USING A REGULARLY

CALIBRATED TORQUE WRENCH.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.

TORCH/WELDING

DO NOT USE A CUTTING TORCH TO REMOVE ANY FASTENERS OR BUSHINGS.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 ADVERSE VEHICLE HANDLING AND

POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF THE

EQUALIZING BEAM. DO NOT CONNECT ARC WELDING GROUND LINE TO THE EQUALIZING BEAM. DO

NOT STRIKE AN ARC WITH THE ELECTRODE ON THE EQUALIZING BEAM AND AXLE. DO NOT USE HEAT

NEAR THE EQUALIZING BEAM ASSEMBLY. DO NOT NICK OR GOUGE THE EQUALIZING BEAM. SUCH

IMPROPER ACTIONS CAN DAMAGE THE EQUALIZING BEAM ASSEMBLY AND CAUSE ADVERSE VEHICLE

HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

LOAD CAPACITY

ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION. ADD-ON AXLE ATTACHMENTS

AND OTHER LOADTRANSFERRING DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED

AND APPROVED CAPACITIES, WHICH CAN RESULT IN COMPONENT DAMAGE AND ADVERSE VEHICLE

HANDLING, POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

MODIFYING COMPONENTS

DO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON. DO NOT

USE SUBSTITUTE OR 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,

ADVERSE VEHICLE HANDLING,AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE AND WILL

VOID WARRANTY. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.

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.

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 JEOPARDIZED 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.

617730-299

ULTIMAAX®for Fire and Rescue Vehicles

SUPPORT THE VEHICLE PRIOR TO SERVICING

PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO PREVENT THE VEHICLE FROM

MOVING OR ROLLING. DO NOT WORK AROUND OR UNDER A RAISED VEHICLE SUPPORTED BY ONLY

A FLOOR JACK OR OTHER LIFTING DEVICE.ALWAYS SUPPORT A RAISED VEHICLE WITH RIGID SAFETY

STANDS.FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY OR DAMAGE TO EQUIPMENT.

IMPROPER JACKING METHOD

IMPROPER JACKING METHODS CAN CAUSE STRUCTURAL DAMAGE WHICH CAN CAUSE ADVERSE

VEHICLE HANDLING, PROPERTY DAMAGE OR SEVERE PERSONAL INJURY AND WILL VOID

HENDRICKSON’S WARRANTY.

■ DO NOT USE THE SUSPENSION CROSS TUBE AS A JACKING POINT, SEE FIGURE 3-1, REFER TO

VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.

■ ACCEPTABLE LIFTING POINTS FOR A VEHICLE AT THE RATED LOAD INCLUDE BUT ARE NOT

LIMITED TO:THE AXLE, EQUALIZING BEAM, AND THE VEHICLE FRAME RAIL. REFER TO THE VEHICLE

MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.

FIGURE 3-1

SADDLE CONNECTION

A SADDLE ASSEMBLY IS ATTACHED TO THE CENTER BUSHING OF EACH EQUALIZING BEAM WITH TWO

(2) SADDLE CAPS. EACH SADDLE CAP USES TWO (2) BOLTS TO CLAMP THE CENTER BUSHING INNER

METAL TO THE SADDLE. EACH SADDLE CAP MUST BE INSTALLED SO THAT THERE IS AN EVEN GAP

BETWEEN THE SADDLE CAP AND THE BASE OF THE SADDLE LEGS AS SHOWN IN FIGURE 3-2.IF EACH

SADDLE CAP IS NOT INSTALLED EVENLY,THE SADDLE LEGS COULD BECOME DEFORMED, RESULTING

IN BENT BOLTS OR DAMAGED SADDLES.

FIGURE 3-2

Equalizing

Beam

Center Bushing

greaseDO NOT

Cross Tube

grease or

use as a jacking point

DO NOT

63K ShownULTIMAAX

17730-299 7

ULTIMAAX®for Fire and Rescue Vehicles

TORQUE ROD ASSEMBLY

THE ULTIMAAX SUSPENSION INCORPORATES LONGITUDINAL AND TRANSVERSE TORQUE RODS FOR

VEHICLE STABILITY. IF THESE COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL THE

VEHICLE SHOULD NOT BE OPERATED. FAILURETO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING

AND POSSIBLE TIRE CONTACT WITH THE FRAME OR THE SUSPENSION.

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 GASOLINE OR 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 GROUND OR

POLISHED PARTS. DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY.

817730-299

ULTIMAAX®for Fire and Rescue Vehicles

SECTION 4

Special Tools

SADDLE TOOLS

DISASSEMBLY TOOL

Hendrickson Part No. 66086-113L

ASSEMBLY TOOL

Hendrickson Part No. 66086-108L

CENTER BUSHING TOOLS

RECEIVING TOOL

Hendrickson Part No. 66086-112

INSTALLATION TOOL

Hendrickson Part No. 66086-107

REMOVAL TOOL

Hendrickson Part No. 66086-110

BAR PIN STYLE END BUSHING TOOLS – 54K • 58K

RECEIVING TOOL

Hendrickson Part No. 66086-111

INSTALLATION TOOL

Hendrickson Part No. 66086-106

REMOVAL TOOL

Hendrickson Part No. 66086-109

ADAPTER STYLE END BUSHING TOOLS – 63K

End Bushing

Removal / Replacement Adapter

OTC Part Number 208350

Clamp

OTC Part Number 208349

Center Bushing

Removal / Replacement Adapter

OTC Part Number 28541

Not Needed for this publication

Hendrickson Part No. 66086-101

OTC Part No. 1763

Visit otctools.com

17730-299 9

ULTIMAAX®for Fire and Rescue Vehicles

TORQUE ROD BUSHING TOOLS

These shop made tools are made from cold rolled steel or equivalent.The drawings are

for reference only, Hendrickson does not supply these tools.

RECEIVING TOOL INSTALLATION / REMOVAL TOOL ULTRA ROD PLUS FUNNEL TOOL

Hendrickson Part No. 66086-000L

10 17730-299

ULTIMAAX®for Fire and Rescue Vehicles

SECTION 5

Parts List

■ 54K – Rosenbauer 9½" Ride Height • KME 10" Ride Height

■ 58K – Seagrave 9½", 10¼" and 11½" Ride Height

■ 63K – Rosenbauer 10½" Ride Height, KME 10" Ride Height

63K Beam End Conguration

(if equipped)

14 (if equipped)

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