Hendrickson OPTIMAAX Operating instructions

OPTIMAAX®Lift Axle System
Air Controller Module for
Freightliner Vehicles
SUBJECT: Service Instructions
LIT NO: 17730-310
DATE: July 2018 REVISION: A
TABLE OF CONTENTS
Section 1 Introduction ......................2
Section 2 Product Description ...............2
Section 3 Important Safety Notice ............4
Section 4 Denitions .......................8
Section 5 Parts List.........................9
Section 6 Air Controller Module............ 10
Section 7 Wiring Diagram................. 11
Section 8 Preventive Maintenance.......... 12
Section 9 Air Controller Manifold Diagram... 13
Section 10 Vehicle Air Plumbing Diagram .... 15
Section 11 System Operation ............... 16
Section 12 Diagnostic Tool Software ......... 17
Section 13 Troubleshooting Guide ........... 21
Electronic Components............. 21
Fault Codes...................... 23

Introduction 217730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 1
Introduction
This publication is intended to acquaint and assist maintenance personnel in the preventive
maintenance,service,repair and rebuild of the air controller module for Hendrickson’s OPTIMAAX®
Lift Axle System for Freightliner vehicles.
NOTE Use only Hendrickson genuine parts for servicing this system.
Alteration of the OPTIMAAX system air controller module is not permitted.
It is important to read and understand the entire Technical Procedure publication prior to instal-
lation or 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 OPTIMAAX system air controller.
Hendrickson reserves the right to make changes and improvements to its products and publications
at any time. Contact Hendrickson Truck 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].
SECTION 2
Product Description
Hendrickson’s OPTIMAAX system is a 6 × 2 solution to help fleets save fuel cost, tire wear and
weight with comparable handling to 6 × 4 tandem axle configurations. Operating as a liftable
axle in the forward tandem position, this system provides versatility for fleets with variable loads.
The OPTIMAAX system air controller monitors air pressure in the drive axle suspension,and calcu-
lates axle load based on air pressure levels.When load reaches a set threshold (programmed by
Hendrickson,where the limiting factor is typically steer axle load) the OPTIMAAX lift axle automati-
cally deploys.The OPTIMAAX system air controller module includes the air controller manifold,
electronic control unit (ECU),and the wiring harness (supplied by Freightliner).
Proprietary program logic controls lift axle movement, load transfer and braking functions.
■ Fully automated controls — Eliminates driver intervention versus conventional 6x2 manual
control systems.Automates axle lowering and lifting by sensing load capacities.
■ Optimized traction and handling — Lifted axle position provides increased traction by
increasing drive axle load.Improved traction when backing under trailers in soft soil or wet
conditions versus traditional 6 x 2 configuration.Maintains vehicle handling characteristics by
keeping the drive axle behind the fifth wheel.

17730-310 3Product Description
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
FIGURE 2-1 Air Controller Manifold
FIGURE 2-2 Electronic Control Unit (ECU)
FIGURE 2-3 Air Controller Wiring Harness (Supplied by Freightliner)
Freightliner Part No.A06-95715
HARN-AXLE-LIFT, CHAS, HDR
Freightliner Part No.A06-95709
HARN-AXLE-LIFT, DASH, HDR, P4

Important Safety Notice 417730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 3
Important Safety Notice
Proper maintenance, service, and repair is important for 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 it unsafe in operation, or void manufacturer’s warranty.
Failure to follow the safety precautions in this manual can result in personal injury and / or prop-
erty 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 importance 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, COULD RESULT IN SERIOUS
INJURY OR DEATH.
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 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 SpecialTools 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.
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.

17730-310 5Important Safety Notice
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
■ SAFETY PRECAUTIONS
NOTE REPLACE ANY SAFETY DECALS THAT ARE FADED, TORN, MISSING, ILLEGIBLE, OR OTHERWISE
DAMAGED. CONTACT HENDRICKSON TO ORDER REPLACEMENT LABELS.
LIFT AXLE RAPID AUTOMATIC MOVEMENT
FIGURE 3-1 Product / Safety Decal 60905-048
LIFT AXLE RAPID,AUTOMATIC MOVEMENT CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.
THE LIFT AXLE CONTROL SYSTEM IS PROGRAMMED TO
AUTOMATICALLY:
LOWER THE LIFT AXLE IF –
■ A LOAD ON THE PRIMARY REAR SUSPENSION
IS ABOVE A PRESET VALUE,OR
■ THE PARKING BRAKE IS ENGAGED, OR
■ THE IGNITION SWITCH IS OFF, OR
■ A MAJOR SYSTEM FAULT IS DETECTED
RAISE THE LIFT AXLE IF –
■ 1) THE PARKING BRAKE IS DISENGAGED,
AND 2) A LOAD ON THE PRIMARY REAR
SUSPENSION IS BELOW A PRE-SET VALUE.
LIFT AXLE LOADING / UNLOADING
■ ENSURE ALL PERSONNEL ARE CLEAR OF LIFT AXLE
DURING VEHICLE LOADING / UNLOADING AND
OPERATION.
■ ENGAGE THE PARKING BRAKE DURING VEHICLE
LOADING / UNLOADING.
PRIOR TO SERVICE
■ EXHAUST ALL PRESSURE IN LIFT AXLE AIR SPRINGS AND VEHICLE AIR SYSTEM BEFORE WORKING
ON OR AROUND LIFT AXLE.
■ REMOVE 15 AMP FUSE FROM F15 LOCATION, REFER TO THE SYSTEM OPERATION SECTION OF
THIS PUBLICATION.
AIR CONTROLLER MANIFOLD
HOT AIR CONTROLLER MANIFOLD SURFACE CAN CAUSE BURNS.DO NOT TOUCH.ALLOW MANIFOLD TO
COOL BEFORE SERVICING,SEE FIGURES 3-2 AND 3-3.
FIGURE 3-2 FIGURE 3-3
ELECTRICAL SYSTEM
DO NOT WORK ON THE VEHICLE ELECTRICAL SYSTEM WITH THE VEHICLE POWER ON. DAMAGE TO
VEHICLE ELECTRICAL SYSTEM AND / OR UNEXPECTED AXLE MOVEMENT MAY RESULT.

Important Safety Notice 617730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
WIRING HARNESS
ENSURE THERE IS SUFFICIENT FREE MOVEMENT IN AIR CONTROLLER WIRING HARNESS TO PREVENT
WIRES AND CONNECTIONS FROM BEING UNDER TENSION DURING INSTALLATION.FAILURE TO DO SO
MAY DAMAGE OR FRAY THE CABLES.
SYSTEM INSTALLATION
IT IS THE RESPONSIBILITY OF THE INSTALLER OF THE AIR CONTROLLER MODULE AND OTHER OPTIMAAX
SYSTEM COMPONENTS TO ENSURE PROPER INSTALLATION.ANY INSTALLATION DEVIATIONS MUST
BE APPROVED, IN WRITING, BY HENDRICKSON’S PRODUCT ENGINEERING DEPARTMENT.ANNUAL
INSPECTION OF SYSTEM PRESSURE SENSORS IS REQUIRED TO CHECK FOR PROPER LOADING ON
DRIVE AXLE AND STEER AXLE. FAILURE TO COMPLY WITH ANY OF THE ABOVE WILL VOID APPLICABLE
WARRANTIES.
AIR SPRING INFLATION AND DEFLATION
PRIOR TO DISASSEMBLY OF THE SUSPENSION, AIR SPRING ASSEMBLIES MUST BE DEFLATED.
UNRESTRICTED AIR SPRING ASSEMBLIES CAN VIOLENTLY SHIFT. DO NOT INFLATE AIR SPRING
ASSEMBLIES WHEN THEY ARE UNRESTRICTED. AIR SPRING ASSEMBLIES MUST BE RESTRICTED
BY SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE BEYOND PRESSURES
RECOMMENDED BY AIR SPRING MANUFACTURER, CONTACT HENDRICKSON TECHNICAL SERVICES
FOR DETAILS. IMPROPER USE OR OVER INFLATION MAY CAUSE AIR SPRING ASSEMBLIES TO BURST,
CAUSING PROPERTY DAMAGE AND / OR SEVERE PERSONAL INJURY.
PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM, ENSURE ALL
PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND AROUND THE SERVICE
AREA, FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY, DEATH,OR PROPERTY DAMAGE.
AIR SPRING INFLATION
INFLATE THE SUSPENSION SLOWLY AND MAKE SURE THE RUBBER BLADDER OF THE AIR SPRING
INFLATES UNIFORMLY AND IS NOT BINDING. FAILURE TO DO SO CAN CAUSE DAMAGE TO THE AIR
SPRING AND / OR MOUNTING BRACKETS AND VOID WARRANTY.
AIR SPRING LOWER MOUNTING STUDS
IF THE AIR SPRING IS BEING REMOVED FOR AN ALTERNATE REPAIR,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.
PROCEDURES AND TOOLS
A MECHANIC 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 ASSUME ALL RISKS OF POTENTIAL PERSONAL INJURY OR
DAMAGE TO EQUIPMENT INVOLVED.
PERSONNEL 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.
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 OFTHE PART,ADVERSE VEHICLE
HANDLING, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE,AND WILL VOID ANY APPLICABLE
WARRANTIES. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS.

17730-310 7Important Safety Notice
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SUPPORT THE VEHICLE PRIOR TO SERVICING
PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE
FROM MOVING. PRIOR TO SERVICING A VEHICLE IN THE RAISED POSITION, PROPERLY SUPPORT THE
VEHICLE WITH SAFETY STANDS. DO NOT WORK AROUND OR UNDER A RAISED VEHICLE SUPPORTED
ONLY WITH FLOOR JACKS OR OTHER LIFTING DEVICES, FAILURE TO DO SO CAN CAUSE DEATH,
PERSONAL INJURY OR DAMAGE TO COMPONENTS.
IMPROPER JACKING METHOD
IMPROPER JACKING METHOD CAN CAUSE STRUCTURAL DAMAGE AND RESULT IN ADVERSE VEHICLE
HANDLING, SEVERE PERSONAL INJURY OR DEATH. DO NOT USE AXLE BEAM OUTBOARD OF AXLE
SPRING SEATS. REFER TO VEHICLE MANUFACTURER FOR PROPER JACKING INSTRUCTIONS.
SUPPORT THE LIFT AXLE PRIOR TO SERVICING
PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE
FROM MOVING. PRIOR TO SERVICING A LIFT AXLE IN THE RAISED POSITION, (1) PROPERLY SUPPORT
THE LIFT AXLE WITH SAFETY STANDS,AND (2) RELEASE ALL AIR PRESSURE IN THE LIFT AXLE AIR
SPRINGS AND RIDE SPRINGS. DO NOT WORK AROUND OR UNDER A RAISED LIFT AXLE SUPPORTED
ONLY WITH FLOOR JACKS OR OTHER LIFTING DEVICES, FAILURE TO DO SO CAN CAUSE DEATH,
PERSONAL INJURY OR DAMAGE TO COMPONENTS.

Denitions 817730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 4
Definitions
DEFINITIONS
APU Auxiliary Power Unit
Bobtail Condition A bobtail truck is a semi-truck that travels from one point to another
without a trailer.
CAN BUS Controller Area Network Bus
CAN Wires Controller Area Network Wires
Cong File License le needed to run the Diagnostic Tool Software.Controlled
by Hendrickson.
Diagnostic tool
Software Software used to communicate with the lift axle
ECU Electronic Control Unit
EEPROM Electrically Erasable Programmable Read-only Memory
OBD On-board Diagnostics
sSAM Single Signal-detection and Activation Module
USB Universal Serial Bus
VPDM Vehicle Power Distribution Module

17730-310 9Parts List
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 5
Parts List
No. 60905-051
***12
***13.
Tightening Torque
53 ± 9 in. lbs.
***13.
Tightening Torque
53 ± 9 in. lbs.
***12
3
8
**5,6
9
4
**7
10
2
11
KEY NO. PART NO. DESCRIPTION VEHICLE
QUANTITY
TORQUE
VALUE
1 80692-0XX *OPTIMAAX Air Controller Module, Includes Key Nos.2-3,8 1
2 60905-051 Warning Decal 2
3 80427-0XX Electronic Control Unit (ECU),Includes Key Nos.4-7 1
4 60905-052 OPTIMAAX ECU Decal 1
5**ECU Hardware 1
6**OPTIMAAX EEPROM 1
7**OPTIMAAX Programing Decal 1
8 80860-000 Splash Shield Assembly, Includes Key Nos. 9-11 1
9 60905-030 Manifold Heat Warning Decal 1
10 77276-000 Splash Shield 1
11 80426-000 Air Controller Manifold 1
12 ***M5 x 16 mm Screw 6
13 ***M5 Flange Hex Nut 653 ± 9 in lbs.
NOTE: * Consult the vehicle manufacturer for applicable OPTIMAAX Air Controller Module.
** Item included in kit / assembly only, part not sold separately.
*** Fasteners and torque value supplied by vehicle manufacturer.Contact vehicle manufacturer for additional service information.

Air Controller Module 10 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 6
Air Controller Module
INSTALLATION
ASSEMBLY
1. Prior to installation of air controller module, refer to Cautions and Warnings in the Important
Safety Notice Section of this publication
DO NOT WORK ON THE VEHICLE ELECTRICAL SYSTEM WITH THE VEHICLE POWER ON. DAMAGE TO
VEHICLE ELECTRICAL SYSTEM AND / OR UNEXPECTED AXLE MOVEMENT MAY RESULT.
NOTE Refer to Wiring Diagram Section of this publication for basic routing / schematic of wires.
2. Chock the wheels and exhaust all air from the vehicle supply tanks.
PRIOR TO AND DURING DEFLATION AND INFLATION OF THE AIR SUSPENSION SYSTEM,ENSURE THAT ALL
PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDERTHE VEHICLE AND AROUNDTHE SERVICE AREA,
FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY,DEATH, OR PROPERTY DAMAGE.
3. See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this
publication prior to deflating or inflating the air system.
4. Ensure vehicle power is off.
5. Remove 15 AMP fuse from slot F15 located in the dash board behind VPDM, see Figure 11-2
in System Operation Section of this publication.
6. Ensure the wiring harness is plugged into the ECU and air controller manifold per the vehicle
manufacturer’s specifications. Harness connectors have printing (A,B,C,D,E) to indicate
which manifold connectors to mate with.The manifold is engraved with matching letters,see
Wiring Diagram Section of this publication.
■ The wiring harness pressure connector labeled DRIVE matches the manifold port
engraved DRIVE.The harness pressure connector labeled LIFT matches with the remain-
ing manifold port.
■ Ensure the wiring harness is secured as per vehicle manufacturer’s guidelines.For worn or
frayed harness, contact the vehicle manufacturer.
DO NOT WORK ON THE VEHICLE ELECTRICAL SYSTEM WITH THE VEHICLE POWER ON. DAMAGE TO
VEHICLE ELECTRICAL SYSTEM AND / OR UNEXPECTED AXLE MOVEMENT MAY RESULT.
7. Connect the lift axle air plumbing to the OPTIMAAX air manifold per Air Manifold Diagram
Section of this publication.
8. Install splash shield over OPTIMAAX ECU.
9. See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this
publication prior to deflating or inflating the air system.
10. Reconnect vehicle power and start the engine.
11. Re-insert 15 AMP fuse in slot F15 located in the dash board behind VPDM.
12. Allow compressor to generate full system pressure.With wheels still chocked, cycle vehicle
parking brake to verify system operation.
■ Lift axle should always remain on the ground with the parking brake set.At bobtail condi-
tion the lift axle should raise when the parking brake is released.
13. Remove the wheel chocks.

17730-310 11 Wiring Diagram
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 7
Wiring Diagram
ELECTRONIC CONTROL UNIT for AIR CONTROLS
ECU
Part Number
Deploy Threshold
lbs
Retract Threshold
lbs
080427-001 11000 12000
080427-002 12000 13000
080427-003 13000 14000
080427-004 14000 15000
080427-005 15000 16000
080427-006 16000 17000
080427-007 17000 18000
080427-008 18000 19000
THE ADDITION OF WEIGHT TO THE VEHICLE (APU - AUXILIARY POWER UNIT, CHAINS, ETC.) MAY CHANGE
THE CORRECT OPTIMAAX DEPLOY THRESHOLD AND MAY REQUIRE REPLACEMENT OF THE ECU. FAILURE
TO DO SO WILL OVERLOAD THE LIFT AXLE.
CANBUS
12V
Ignition
OPTIMAAX
ECU
OPTIMAAX
Air Controller
Manifold
Warning
Light Drive
Lift
A
B
C
D
E

Preventive Maintenance 12 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 8
Preventive Maintenance
AIR CONTROLLER MANIFOLD
Appropriate inspection procedure is important to ensure the OPTIMAAX system is accurately mea-
suring the system load.
■ On an annual basis – the calibration of the pressure sensors, see Figure 8-1, in the air con-
troller manifold must be checked.
INSPECTION
1. Connect the Diagnostic Tool Software.
2. Apply shop air to the drive port with a calibrated pressure gauge.
3. Displayed pressure in Diagnostic Tool Software must match pressure gauge measurement
within ± 5PSI.If not, the air controller manifold must be replaced.
4. Repeat Steps 2 and 3 for the lift port.
FIGURE 8-1
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
Displayed pressure
must match the
Pressure Gauge
measurement

17730-310 13 Air Controller Manifold Diagram
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 9
Air Controller Manifold Diagram
TUBING REPLACEMENT
FOR THE AIR PORT EXH ON THE AIR CONTROLLER MANIFOLD, USE A FILTER RATED TO AT LEAST 40
MICRON.ANYTHING LESS CAN CAUSE DAMAGE TO THE AIR CONTROL PANEL.
1. Use only S.A.E. J844 tubing and ensure all tubes are free from kinks.
2. Ensure that the minimum bend radius is achieved on all tubes prior to assembly.
Recommended minimum radius:
■¼" Tube – 1.0 inches ■3⁄8" Tube – 1.5 inches ■½" Tube – 2.0 inches
3. Use only dedicated tube cutters when preparing tube ends for insertion into push-in fittings.
4. Ensure the tube ends are square,free of damage, and clean.
5. Ensure the tube is fully inserted into the fittings (tube ends are pushed past both the grip ring
and the sealing O-ring).
■ SUPPLY and LIFT ½" tubes (not supplied by Hendrickson)
■ AUX and DRIVE 3⁄8" tubes (not supplied by Hendrickson)
6. A spring is used to retain a mesh filter on DRIVE and SUPPLY ports.These must be retained
when PTC fittings are installed (not supplied by Hendrickson).The mesh filter helps to prevent
debris from entering the system.
7. Ensure the tubing is not under any tension.
ECU
Output from Manifold:
Lift Spring
Input to Manifold:
Drive Suspension Pressure
Input to Manifold:
Air Supply
Air Controller
Manifold
*/"Tube
38AUX
(Black)
*½"TubeSUPPLY
(Yellow)
*/"
38DRIVE Tube
(Blue)
*½"TubeLIFT
(Blue)
*NPT PTC Fittings are not supplied by Hendrickson
EXH Filter
Output from Manifold:
Aux Ride Spring

Air Controller Manifold Diagram 14 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
Air Port
AUX
Air Port
LIFT
Air Port SUPPLY Air Port EXH
Electrical Port A
Electrical Port B
Electrical Port C
Air Port
DRIVE
Electrical Port DElectrical Port E
Electrical Port
DRIVE
Electrical Port
LIFT
OPTIMAAX AIR CONTROLLER MANIFOLD
AIR AND ELECTRICAL PORTS
TOP VIEW
FRONT VIEW
BOTTOM VIEW
SIDE VIEW

17730-310 15 Vehicle Air Plumbing Diagram
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 10
Vehicle Air Plumbing Diagram
Air Supply - Height Control Valve
Air Supply - Manifold
Air Signal - Brake Signal
Air Controller Manifold
Output from
Manifold:
Lift Spring
Output from Manifold:
Auxiliary Ride Spring
Input to Manifold:
Drive Suspension Pressure
Drive Axle
Height Control Valve

System Operation 16 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 11
System Operation
Prior to operating the system, refer to Safety Precautions in the Important Safety Notice Section
of this publication.
SYSTEM FAULT
The OPTIMAAX is designed with features to detect a fault in system operation which is separate
from the air controller module.The warning light on the dashboard, see Figure 11-1, indicates
either of the following conditions:
FIGURE 11-1
A FLASHING WARNING LIGHT indicates a system fault. Refer to the
Diagnostic Tool Software Section for reading ECU system faults and the
Troubleshooting Guide Section of this publication.
A SOLID WARNING LIGHT indicates an overload condition of the
suspension. It may be benecial to weigh the vehicle to verify overload
condition.The OPTIMAAX system is designed to help ensure that the lift, drive,
and steer axles operate within the proper weight parameters.An overload
light will indicate an overload on at least one of the axles.
Prior to service of the lift axle,adjacent components or the air controller module:
a. Turn ignition off.
b. Ensure the lift axle is on ground.
c. Remove 15 AMP Fuse, located in the dash behind the vehicle power distribution module
(VPDM) in location F15, which houses the main fuse and relay center,see Figure 11-2.
d. Exhaust all pressure in lift axle air springs and vehicle air system.
NOTE The OPTIMAAX air controller module weight thresholds to raise and deploy the lift axle are set by
vehicle manufacturer.
FIGURE 11-2
Vehicle Power
Distribution Module
(VPDM)
F15
F15
Remove 15 AMP Fuse
from slot F15,located in the
dash board behind the VPDM

17730-310 17 Diagnostic Tool Software
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
SECTION 12
Diagnostic Tool Software
FEATURES AND OPERATION
SYSTEM MINIMUM REQUIREMENTS AND OPERATING SYSTEMS
This Diagnostic Tool Software works with a laptop equipped with a 32-bit or 64-bit Windows® X P,
Vista and Windows 7, 8 and 10 operating systems. Hendrickson provides access to software
through NEXIQ, www.nexiq.com.
THE DIAGNOSTIC TOOL SOFTWARE
It is used to communicate with the lift axle controls.It allows the user to monitor system function,
and troubleshoot system operation.
SERIAL PORT AND USB TO SERIAL CABLE
The serial port must be selected in the Diagnostic Tool Software.If using a USB to serial converter,
the software for the USB device must be installed first and connected to the computer to check
the settings.
FIGURE 12-1
OPENING THE DIAGNOSTIC TOOL SOFTWARE
You will need:
■ USB to RS232 Cable 6.26' (2.00m) Shielded (not supplied),see
Figure 12-1.
Manufacturer: Future Technology Devices International Ltd.
Part Number: UT232R-200
1. Locate the serial port cable, typically located in the dash behind the vehicle power distribu-
tion module (VPDM) which houses the main fuse and relay center,and plug into it using the
USB to serial cable, see Figure 12-1.
2. With the ignition on and parking brake engaged, open the Diagnostic Tool Software, see
Figure 12-2.
3. DO NOT turn off the vehicle power when the software is open. It is recommended to keep the
engine running while connected so the air is available to test system operation.
4. Select a COM port from the pull down menu,see Figure 12-2.Select one port and click Open.
5. If the wrong COM port is selected, the software will show an Error message as shown in
Figure 12-3.Select another COM port until the software opens.
6. Once the connection is made,the software version and serial number will be displayed in the
white box,see Figure 12-4.
7. Click on the History tab to view error / fault codes,see Figures 12-4 and 12-6.

Diagnostic Tool Software 18 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
FIGURE 12-2
FIGURE 12-3
FIGURE 12-4
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
Select a COM Port
from the pull down menu.
There may be more than
one com port available.
Pick one,
and click Open
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
Select another COM Port
untill the software opens
and Select OK
If the wrong
COM Port is selected,
the software will show
an Error message
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
The screen will look
like this when the
software is
communicating
with the controller
Click on the
History tab
to view error /
fault codes

17730-310 19 Diagnostic Tool Software
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
FIGURE 12-5
FIGURE 12-6
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
Digital #2
Represents the
parking brake signal
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
Click on History
to view
ASECU current
error / fault codes Click here to view
ASECU Log Data

Diagnostic Tool Software 20 17730-310
OPTIMAAX®Lift Axle System Air Controller Module for Freightliner
EXITING THE DIAGNOSTIC TOOL SOFTWARE
ALWAYS EXIT THE DIAGNOSTIC TOOL SOFTWARE PROPERLY, ONLY DISCONNECT THE CABLE AFTER
EXITING THE SOFTWARE.FAILURE TO DO SO CAN CORRUPT INFORMATION STORED ON THE ECU.
Always exit and open the Diagnostic Tool Software properly.
1. Prior to exiting the Diagnostic Tool Software,ENGAGE the parking brake.
2. Press the CLOSE button on the START tab to terminate communication with the lift axle ECU,
see Figure 12-7.
3. Exit the window, see Figure 12-7.
FIGURE 12-7
Hendrickson OPTIMAAX Diagnostic Tool
File Log Tools Help
STEP 2
Click Close to exit
STEP 3
Exit window