D11205 Rev C 11/15
DS150FR-S
Issues with One Corner Not Leveling Properly ............. 43
Issues with Height Sensors ............................................ 43
Issues with Ride/Handling ............................................. 43
Issues with Steering Sensor ........................................... 43
Issues with Vehicle Speed Signal ................................... 44
Issues with Vehicle Brake Signal ................................... 44
Issues with Door Switch................................................. 44
Issues with Vehicle Ignition Signal ................................ 44
Issues with Vehicle Park Signal ..................................... 44
Issues with Driver Interface ........................................... 44
Issues with Power Module ............................................. 45
Issues with Strut Assembly ............................................. 45
Issues with Secondary Volume Assembly ....................... 46
Contents
CONTENTS ........................................................................... 2
INTRODUCTION ................................................................. 3
SUSPENSION APPLICATION ................................................... 3
SUSPENSION RATING ............................................................ 3
SERIAL NUMBER TAG INFORMATION .................................... 3
VEHICLE TOWING AND JACKING INFORMATION ................... 4
ABBREVIATIONS ................................................................ 4
SPECIAL TOOLS ................................................................. 4
HYDRAULIC FITTING ASSEMBLY ................................ 5
SAE O-Ring Adjustable Fittings ...................................... 5
SAE O-Ring Non-Adjustable Fitting ................................ 5
JIC 37° Fitting ................................................................. 5
PRE-INSTALLATION.......................................................... 5
PART IDENTIFICATION: ................................................ 47
DS150FR-S........................................................................ 47
DS150FR-SF ..................................................................... 49
DS150FR-SS ..................................................................... 51
FRAME PREPARATION ..................................................... 5
ELECTRICAL SCHEMATICS ......................................... 53
AXLE PREPARATION ........................................................ 6
APPENDIX A: DRILL LOCATIONS .............................. 56
INSTALLATION ................................................................... 8
FRONT HANGERS .................................................................. 8
AXLE CONNECTION .............................................................. 9
CONTROL ARMS ................................................................. 10
UPPER STRUT MOUNTS ....................................................... 11
TRACK ROD ........................................................................ 13
STRUTS ............................................................................... 14
JOUNCE STOPS .................................................................... 15
SECONDARY VOLUMES [DS150FR-S] ................................ 16
SECONDARY VOLUMES [DS150FR-SF] .............................. 18
SECONDARY VOLUMES [DS150FR-SS] .............................. 20
POWER MODULE ................................................................. 22
HOSE ATTACHMENT AND ROUTING [DS150FR-S] ............. 23
HOSE ATTACHMENT AND ROUTING [DS150FR-SF] ........... 25
HOSE ATTACHMENT AND ROUTING [DS150FR-SS] ........... 27
HEIGHT SENSORS ................................................................ 29
STEERING SENSORS ............................................................ 30
WIRING ............................................................................... 32
Optional Door Electrical Harness Installation: ............ 36
APPENDIX B: ELECTRICAL TERMINALS ................ 58
INSTALLATION CHECK LIST ....................................... 59
SYSTEM PREPARATION ................................................. 37
Initial System Fill ........................................................... 37
Bleeding the System ....................................................... 37
Calibrating the System ................................................... 37
POST INSTALLATION WELDING........................................... 38
SYSTEM OPERATION ...................................................... 39
System Start Up: ............................................................ 39
ON/OFF Button: ............................................................ 39
Warning Light: ............................................................... 39
Ride Mode Adjustment: .................................................. 39
Ride Height Adjustment: ................................................ 39
Depressurizing the System ............................................. 40
Calibrating the Steering Sensor Only ............................ 41
TROUBLESHOOTING ...................................................... 42
Issues with Vehicle Raising/Pump ................................. 42
Issues with Vehicle Lowering/Dump Valve .................... 42
2
DS150FR-S
Introduction
Suspension Rating
This manual provides installation information for the
LiquidSpring CLASS® DS150FR series of rear axle
suspension systems for the Freightliner M2 106 series of
chassis.
The LiquidSpring line of DS150FR suspensions can be used
on the hydraulic brake versions of Freightliner M2 106
chassis. Suspension ratings are based on the OEM rear axle
rating of each chassis:
Model
DS150FR-S
DS150FR-SF
DS150FR-SS
Before you begin installation of the suspension system:
1.
Read and understand all instructions and procedures
prior to installation of components.
2.
Read and observe all Warning and Caution hazard
alert messages in this publication. They provide
information that can help prevent serious personal
injury, damage to components, or both.
3.
Follow your company’s maintenance and service,
installation, and diagnostics guidelines.
4.
Use special tools when required to help avoid serious
personal injury and damage to components.
Freightliner M2 106
15,000 lbs
15,000 lbs
15,000 lbs
The rear axle GAWR with LiquidSpring DS150FR installed is
the lessor of either the OEM original rear rating (as published)
or the above suspension rating.
WARNING: Overloading suspension system may result in
abnormal handling characteristics and premature wear of
components.
Serial Number Tag Information
The serial number is found on an aluminum tag (Figure 1) that
is riveted to the Left Hand Suspension Hanger as shown in
Figure 2. This information will aid you when contacting the
chassis manufacturer or LiquidSpring LLC.
Throughout this manual, important product information is
preceded by the terms “NOTE”, “IMPORTANT”,
“CAUTION”, and “WARNING”. These terms are defined as
follows:
NOTE: Includes additional information to enable accurate
and easy performance of procedures.
IMPORTANT: Includes additional information that if not
followed could lead to hindered product performance
and/or product failure.
CAUTION: A caution indicates procedures that must be
followed exactly. Damage to equipment or suspension
components and personal injury can occur if the procedure is
not followed.
Figure 1. Serial Tag
WARNING: A warning indicates procedures that must be
followed exactly. Serious personal injury can occur if the
procedure is not followed.
LiquidSpring LLC reserves the right to modify the suspension
and/or procedures and to change specifications at any time
without notice and without incurring obligation.
Suspension Application
Figure 2. Serial Number Tag Location
LiquidSpring offers two (3) versions of the DS150FR line of
suspensions:
Suspension
DS150FR-S
DS150FR-SF
DS150FR-SS
Application
Conversion of Leaf Spring version with
under/behind cab mounted fuel tank.
Conversion of Leaf Spring version with
under/behind cab mounted fuel tank and
shortened rear overhang.
Conversion of Leaf Spring version with
under cab mounted fuel tank.
3
DS150FR-S
Vehicle Towing and Jacking Information
WARNING: Attaching towing equipment to improper
locations and failure to utilize OEM/Coach Builder
recommended towing methods could result in one or more
of the following:
Before attempting any type of towing procedures, the vehicle
manufacturer must be referred to for the recommended towing
methods.
NOTE: Before towing vehicle, check with local authorities,
such as Department of Transportation, for permissible towing
methods. Some states do not permit towing vehicles by chains
or towing straps.
Damage to the suspension and/or vehicle,
Loss of vehicle control,
Possible disconnect from the vehicle.
Do not attach tow apparatus (hooks, chains, straps, etc.) to the
suspension components.
WARNING: Do not apply jack to bottom of front hanger
or other suspension components. Appling a jack to
improper locations can result in damage to the suspension
and/or vehicle and severe personal injury.
Abbreviations
The following abbreviations will be used throughout the
manual.
HCS
Hex Cap Screw
HFB
Hex Flange Bolt
SHCS
Socket Head Cap Screw
SFHS
Serrated Flange Hex Screw
STS
Self Tapping Screw
HN
Hex Nut, Non-locking
LHN
Locking Hex Nut
LFN
Locking Flange Nut
CHN
Castle Hex Nut
HTCN Hex Thin Castle Nut
HFW
Hardened Flat Washer
SLW
Spring Lock Washer
FW
Flat Washer
SAE
SAE O-Ring Fitting
37°
SAE or JIC 37° Flare Fitting (F – Female)
LH
Left Handed Part
RH
Right Handed Part
UCA
Upper Control Arm
LCA
Lower Control Arm
Special Tools
The following tools can assist in installation of the
LiquidSpring system.
Gallon Hand Pump (Autotec 57429 shown, other similar)
Bleed Kit (Actron 7840 shown, others similar).
4
DS150FR-S
Hydraulic Fitting Assembly
2.
If O-ring or seal is not pre-installed to fitting male
port end, install proper size O-ring or seal, taking
care not to damage it.
3.
Lubricate O-ring with light coat of the system fluid or
a compatible lubricant to help the O-ring slide
smoothly into the port and avoid damage.
4.
Screw fitting into port and tighten to proper torque:
-4 fitting: 26-28 ft-lbs (310-341 in-lbs)
-12 fitting: 75-83 ft-lbs.
SAE O-Ring Adjustable Fittings
JIC 37° Fitting
1. Inspect components to ensure that male and female
threads and sealing surfaces are free of burrs, nicks
and scratches, or any foreign material. Annular tool
marks of 100µin with the thread are permissible.
Figure 3. Adjustable SAE fitting
1.
Inspect components to ensure that male and female
port threads and sealing surfaces are free of burrs,
nicks and scratches, or any foreign material.
2.
If O-ring or seal is not pre-installed to fitting male
port end, install proper size O-ring or seal, taking
care not to damage it.
3.
Lubricate O-ring with light coat of the system fluid or
a compatible lubricant to help the O-ring slide
smoothly into the port and avoid damage.
2.
Lubricate the threads and the entire surface of the
cone with system fluid.
3.
Align mating components for hand connection and
turn flare nut until sealing surfaces make full contact.
4.
Using two wrenches, hold fitting in desired position
and tighten to the proper torque:
-4 fitting: 9-12 ft-lbs
-8 fitting: 27-39 ft-lbs
-10 fitting: 36-63 ft-lbs
-12 fitting: 65-88 ft-lbs
Pre-Installation
1.
Check the vehicle rear wheel alignment prior to
installation to insure pre-existing conditions do not
exist.
2.
It is suggested, but not required, to remove the
attached body to ease installation.
3.
A chassis lift can be used in assistance of the
installation of the suspension system.
4.
Measure and record the wheelbase and rear tire-toframe dimensions on each side prior to disassembly.
Figure 4. Locknut completely backed off.
4.
5.
6.
7.
8.
Back off lock nut as far as possible. Make sure backup washer is not loose and is pushed up as far as
possible.
Screw fitting into port until the back-up washer or the
retaining ring contacts face of the port. Light
wrenching may be necessary. Over tightening may
damage washer.
To align the tube end of the fitting to accept
incoming hose assembly, unscrew the fitting by the
required amount, but not more than one full turn.
Frame Preparation
1.
Chock the front tires.
Using two wrenches, hold fitting in desired position
and tighten locknut to the proper torque value:
-4 fitting: 14-16 ft-lbs (168-192 in-lbs)
-12 fitting: 75-83 ft-lbs.
2.
Disconnect battery.
3.
Jack up the rear frame of the vehicle to remove load
from the rear suspension.
Inspect to ensure that O-ring is not pinched and that
washer is seated flat on face of port.
4.
Place jack stands under the frame and block the rear
tires from moving.
Note: Jack stands can be placed under the axle and the
tires removed for ease of access. It is recommended to
place an additional jack stand under the pinion to prevent
the axle from rotating.
SAE O-Ring Non-Adjustable Fitting
1. Inspect components to ensure that male and female
port threads and sealing surfaces are free of burrs,
nicks and scratches, or any foreign material.
5
5.
Remove the air leveling valves and air tanks.
6.
Remove the OEM shock absorbers and mounts.
DS150FR-S
7.
Remove the leaf springs and shackles, if present.
8.
Remove any bump stop bolted on the outboard side
of the frame, directly above the axle.
9.
Remove the front spring hangers. Do not remove
upper (2) bolts per side attaching the cross member to
the frame. Do not remove cross members.
10. The rear shackle hanger or rear spring mounts can
either be removed or left installed.
11. Remove any overload pads mounted outside the
frame rail.
Figure 6, Position Axle Mount using Template
12. Locate the 10811-014 template.
3.
Temporarily attach the template to the axle using the
two differential bolts. Using 5/8” hardware, fasten
the Axle Mount to the template in the position shown
in Figure 6.
15. Repeat with the passenger side.
4.
Outline the axle mount with a visible paint marker.
16. Mark and drill (5) Ø21/32” hole as indicated.
5.
Remove the axle mount from the axle and grind away
the outlined area to bare metal.
13. Attach the frame as indicated in Appendix A: Drill
Locations, Page 56.
14. Mark and drill (5) Ø21/32” holes as indicated.
17. See Secondary Volume Sections for additional frame
drill locations.
Note: Make sure axle housing is free of paint 1/2” beyond the
perimeter of the axle mount.
Axle Preparation
Note: Make sure the axle mount is free of powder coat 1/2”
up from bottom edge around the perimeter.
Note: Freightliner M2 106’s are equipped with either Meritor
or Detroit rear axles. Mounts and templates for both axles are
included in the kit and marked “Meritor” and “Detroit” for use
with the respective axles.
1.
Move any Parking Brake Cables and wiring from top
of axle and position away from the the axle.
2.
Remove the two axle differential bolts as shown in
Figure 5.
6.
Reattach the axle mount to the template after axle
tube is clean and prepped for welding.
7.
Tack weld all 4 sides of the axle mount to the axle
housing as shown in Figure 7
Figure 7, Tack Welding Axle Mount
8.
Remove the template from the axle.
9.
Position axle for a flat weld. The axle must be
pivoted fore and aft for welding front and rear faces.
Figure 5, Removal of Axle Bolts.
Figure 8, Final Welding on Axle Mount
6
DS150FR-S
10. Beginning at the indicated location, back step the
start of the weld from 0.315-0.512” to prevent a cold
start.
11. Lay a full fillet in a single pass: Fillet size 0.3750.50”.
12. Back fill the end of the weld 0.315-0.512” to
eliminate craters.
13. Complete the welding on all sides of the bracket
using Steps 9-12.
14. Once the axle has cooled, reinstall the two M16
differential bolts to the axle using sealant and torque
to 140 ft/lbs.
15. Apply touch up paint to any bare metal showing on
the axle mount and housing.
IMPORTANT: If welding equipment is not capable of
welding a single pass as specified, multiple passes will be
required.
Note: When welding multiple passes, the first pass should be
centered over the fit-up line. The second pass should be
placed slightly above the first. Blend the weld smoothly with
the axle mount and the first pass. The third pass should
penetrate the lower half of the second pass to the edge of the
axle housing. When making the second and third passes the
direction should be reversed. Refer to steps above for back
start and back fill. Clean weld before each pass.
7
DS150FR-S
Installation
Front Hangers
ITEM
1
2
QTY
12
12
PART NUMBER
10012-008
10874-200
DESCRIPTION
LFN 5/8-11 Gr G
HFB 5/8-11 x 2” Gr 8
1.
Install the Left Hand Hanger (with serial tag) to the
driver side of the frame using the (6) 5/8”-11 x 2”
Hex Flange Bolts and 5/8”-11 Locking Flange Nuts.
2.
Verify that the hanger is level to the frame rail.
3.
Torque to 172-210 ft-lbs.
4.
Repeat with Right Hand Hanger to the passenger side
of the frame.
ITEM
3
4
8
QTY
1
1
PART NUMBER
11104-002
11105-002
DESCRIPTION
Left Hand Hanger
Right Hand Hanger
DS150FR-S
Axle Connection
ITEM
1
2
1.
QTY
8
4
PART NUMBER
10012-012
10064-005
DESCRIPTION
LFN 3/4-16, Gr. G
U-Bolt 3/4-16 x 9.03 Tri-8
ITEM
3
4
Loosely install the Upper Control Arm Mount on to
the axle with the UCA clevis forward. The mount
should be flush with the top of the axle with the
locating stud in the center hole. Refer to Figure 9 for
correct orientation.
5.
Figure 9. Control Arm Mount orientation.
2.
Slip the Lower Control Arm Mount under the axle.
3.
Slip the 3/4” U-Bolts under the LCA mount and
secure using the 3/4” Locking Flange Nuts.
4.
Snug down 3/4” Locking Flange Nuts.
QTY
2
2
IMPORTANT: To aid control arm installation,
do not torque until after control arms are
installed.
9
PART NUMBER
10947-005
10949-003
Repeat for other side.
DESCRIPTION
Lower Control Arm Mount
Upper Control Arm Mount
DS150FR-S
Control Arms
ITEM
1
2
3
4
5
1.
QTY
2
2
4
4
4
PART NUMBER
10003-003
10003-004
10006-004
10012-003
10012-008
DESCRIPTION
HCS 1-8 x 6.00 Gr 8
HCS 1-8 x 6.50 Gr 8
HFW 1
LFN 1-8 Gr G
LFN 5/8-11 Gr G
ITEM
6
7
8
9
QTY
2
2
2
2
PART NUMBER
10570-006
10874-375
10874-600
10953-005
DESCRIPTION
Upper Control Arm
HFB 5/8-11 x 3.750 Gr 8
HFB 5/8-11 x 6” Gr. 8
Lower Control Arm
1”-8 x 6” Hex Cap Screw is used to attach the
LCA to the Hanger.
Loosely install the Upper and Lower Control Arms as
shown above.
Note: Orientate Lower Control Arms with height
sensor linkage tabs pointing upward.
2.
Torque U-Bolts as specified in Axle Connection
Section.
IMPORTANT: Fasteners inserted into the axle
mount must be orientated towards the outboard
as shown. Fasteners inserted into the front hanger
can be orientated either direction.
3.
Do not tighten control arm fasteners until track rod is
in place and axle is raised to ride height.
Note: The axle must be held at ride height before
applying the final torque to the control arm bolts to
prevent preloading the bushings.
IMPORTANT: Verify that the 1”-8 x 6-1/2” Hex
Cap Screw is used to attach the Lower Control
Arm to the LCA mount at the axle and that the
10
DS150FR-S
Upper Strut Mounts
ITEM
1
2
3
4
5
QTY
8
12
1
1
1
PART NUMBER
10012-007
10012-008
10790-020
10790-021
10795-008
DESCRIPTION
LFN 1/2-13 Gr G
LFN 5/8-11 Gr G
Upper Strut Mount, LH
Upper Strut Mount, RH
Cross-member Mount, LH
1.
Loosely attach the Left Hand Upper Strut Mount and
Left Hand Cross-member Mount to the frame located
just behind and above the rear axle using (6) 5/8”-11
x 2” Hex Flange Bolts and (6) 5/8”-11 Locking
Flange Nuts. Refer to Figure 10.
2.
Loosely attach the Right Hand Upper Strut Mount
and Right Hand Cross-member Mount to the frame
using (6) 5/8”-11 x 2” Hex Flange Bolts and (6) 5/8”11 Locking Flange Nuts. Refer to Figure 11.
ITEM
6
7
8
9
QTY
1
1
16
8
PART NUMBER
10795-011
10796-007
10874-200
10885-150
DESCRIPTION
Cross-member Mount, RH
Cross-member Channel
HFB 5/8-11 x 2” Gr 8
HFB 1/2-13 x 1-1/2” Gr 8
Figure 10. Driver Side (LH) Upper Strut Mount
Installation.
11
DS150FR-S
Figure 11. Passenger Side (RH) Upper Strut Mount
Installation.
3.
Install the Cross-member Channel inside of the
mounts using the 1/2”-13 x 1-1/2” Hex Flange Bolts
and 1/2”-13 Locking Flange Nuts.
4.
Torque all 5/8” fasteners to 172-210 ft-lbs.
5.
Torque all 1/2” fasteners to 86-105 ft-lbs.
12
DS150FR-S
Track Rod
ITEM
1
2
3
4
QTY
2
2
2
1
PART NUMBER
10002-550
10006-003
10012-017
10811-011
DESCRIPTION
HB 7/8”-9 x 5-1/2” Gr. 8
HFW 7/8”
LFN 7/8”-9 Gr G
Mount Template, Detroit
ITEM
5
6
7
8
QTY
1
1
1
1
PART NUMBER
10811-012
10951-004
10951-005
11198-001
DESCRIPTION
Mount Template, Meritor
Track Rod Mount, Detroit
Track Rod Mount, Meritor
Track Rod Assembly
1.
Loosely attach the Track Rod Assembly to the Track
Rod Axle Mount and to the Frame Mount.
3.
Torque the two (2) 7/8” Track Rod mounting bolts to
491-600 ft-lbs.
2.
Jack each side of the axle until approximately design
ride height position. See Figure 12.
4.
Torque the eight (4) 1” Control Arm mounting bolts
to 600 ft-lbs.
5.
Torque the four (4) 5/8” Control Arm mounting bolts
to 172-210 ft-lbs.
IMPORTANT: Torque all control arm fasteners while
axle is at approximate ride height.
Figure 12, Lift to Design Ride Height.
13
DS150FR-S
Struts
DS150FR-S Strut Installation
DS150FR-SF Strut Installation
DS150FR-SS Strut Installation
ITEM
1
2
3
1.
QTY
4
8
2
PART NUMBER
10012-014
10640-005
11102-400
DESCRIPTION
LFN 3/4-10 Gr G
Bearing Spacer 1.24x.812x.318
HFB 3/4-10 x 4 Gr 8
ITEM
4
5
6
Install the Left Hand Strut assembly as shown
making sure to install bearing spacers on both upper
and lower mounts.
Note: Verify Hydraulic port is pointed rearward on
DS150FR-S and forward on the DS150FR-SF and
DS150FR-SS.
2.
Repeat for installation of Right Hand Strut assembly.
3.
Torque upper and lower strut mounts to 275-300 ftlbs.
14
QTY
2
1
1
PART NUMBER
11102-650
11185-003
11185-004
DESCRIPTION
HFB 3/4-10 x 6-1/2 Gr 8
Asy, Strut (Port pointing right)
Asy, Strut (Port pointing left)
DS150FR-S
Jounce Stops
ITEM
1
QTY
2
PART NUMBER
10502-001
DESCRIPTION
HFB M10-1.5 x 30 CL 10.9
1.
Install Jounce Bumpers, as shown, to the Upper Strut
Mounts.
2.
Torque M10 fasteners to 35 ft-lbs.
ITEM
1
15
QTY
2
PART NUMBER
10867-003
DESCRIPTION
Jounce Bumper 2.375” OD x 3.00” T
DS150FR-S
Secondary Volumes [DS150FR-S]
ITEM
1
2
3
4
5
6
7
QTY
8
4
2
2
1
2
4
PART NUMBER
10012-007
10012-010
10322-010
10597-047
10614-001
10810-014
10830-017
DESCRIPTION
LFN 1/2-13 Gr G
LFN 5/16-18 Gr G
Hyd. Fitting 90 -10 37 x -10 37 F
Volume Asy
Cap, Filler/Breather
Asy, Hose -10 x 18-13/16”
Volume Mount
1.
Using the dimensions given in Figure 53, drill (4)
Ø9/16” holes per side for the volume mounts.
2.
Locate (2) Volume Mounts.
3.
Attach Volume Mounts to the inside of the frame
rails, behind the rear axle, using the 3/8”-16 x 1” Hex
Flange Bolts and 3/8”-16 Locking Flange Nuts.
ITEM
8
9
10
11
12
13
16
QTY
4
4
8
4
1
1
PART NUMBER
10843-003
10855-003
10885-150
10886-125
11013-004
11109
DESCRIPTION
T-Bolt Clamp
Vinyl Coated Loop 5/8” ID
HFB 1/2”-13 x 1-1/2” Gr 8
HFB 5/16”-18 x 1-1/4” Gr 8
Power Module Asy DS150FR
Kit, Power Module Mounting
DS150FR-S
Figure 13. Installation of Volume Mounts.
4.
Torque the 1/2”-13 fasteners to 85-105 ft-lbs.
5.
Locate (2) T-Bolt Clamps, open the mounts, and
place them in the mounts, around the two pegs.
WARNING: Each Volume Assembly is heavy (in excess of
100 lbs). Use of a portable lift, crane, or suitable jack is
recommended to support the Volume Assembly during
installation.
6.
Lift the tank into the tank mounts.
Figure 14. Rear view of volumes installed.
7.
Secure both clamps around the volume and torque the
T-Bolt nut to 240 in-lbs.
8.
Repeat with the other side.
17
DS150FR-S
Secondary Volumes [DS150FR-SF]
ITEM
1
2
3
4
5
6
7
QTY
4
8
1
1
1
2
4
PART NUMBER
10012-007
10012-010
10597-069
10597-070
10614-001
10830-019
10843-003
DESCRIPTION
LFN 1/2”-13 Gr G
LFN 5/16”-18 Gr G
Volume Assembly, LH
Volume Assembly, RH
Cap, Filler/Breather
Volume Mount
T-Bolt Clamp
1.
Locate the (2) Volume Mounts.
2.
Place the mounts against the driver side frame,
forward of the front hanger. Figure 54, in Appendix
A: Drill Locations, shows the suggested locations
ITEM
8
9
10
11
12
13
PART NUMBER
10855-002
10855-003
10885-150
10886-125
11013-004
11109
DESCRIPTION
Vinyl Coated Loop Clamp, 1” ID
Vinyl Coated Loop Clamp, 5/8” ID
HFB 1/2”-13 x 1-1/2” Gr. 8
HFB 5/16”-18 x 1-1/4” Gr 8
Power Module Asy DS150FR
Power Module Mount Kit
the locations of the mounting holes and drill (2)
Ø9/16” holes per mount.
Important: Locate the mounts such that the distance
between two mounts as wide as possible. Avoid
partially drilling through existing frame holes and
inside fuel line mounts.
3.
QTY
5
7
4
8
1
1
4.
Attach the two mounts with 1/2” Flange Bolts and
Nuts. Torque to 86-105 ft-lbs.
5.
Locate the Right Hand Volume Assembly, which
includes the shorter -10 hydraulic hose attached.
WARNING: Each Volume Assembly is heavy (in excess of
100 lbs). Use of a portable lift, crane, or suitable jack is
recommended to support the Volume Assembly during
installation.
Verifying the mounts are held flush to the bottom of
the frame and utilizing the mount hole pattern, mark
18
DS150FR-S
6.
Raise the volume assembly until the volume contacts
both mounts, in the top-most location. Rotate the
volume assembly until the bleed screws are located to
the top and as vertical as possible.
7.
Locate (2) T-Bolt Clamps, open the clamps, and
place them in the mounts around the two pegs.
8.
Secure both clamps around the volume and torque the
T-Bolt nut to 240 in-lbs.
9.
Locate the Left Hand Volume Assembly, which
includes the longer -10 hydraulic hose.
10. Raise the volume assembly until the volume contacts
both mounts. Rotate the volume until the bleed
screws are located to the top and as vertical as
possible.
11. Locate (2) T-Bolt Clamps, open the clamps, and
place them in the mounts around the two pegs.
12. Secure both clamps around the volume and torque the
T-Bolt nut to 240 in-lbs.
19
DS150FR-S
Secondary Volumes [DS150FR-SS]
ITEM
1
2
3
4
5
6
7
QTY
8
10
8
1
1
1
1
PART NUMBER
10012-005
10012-010
10501-002
10597-071
10597-072
10614-001
10830-015
DESCRIPTION
LFN 3/8”-16 Gr G, Z
LFN 5/16”-18 Gr G
HFB 3/8-16 x 1.250, Gr 8, BO
Volume Assembly, LH
Volume Assembly, RH
Cap, Filler/Breather
Wldmnt, Volume Mount
1.
Locate (4) Volume Mounts.
2.
Place the mounts against the driver side frame,
forward of the front hanger. Figure 55, in Appendix
A: Drill Locations, shows the suggested locations
ITEM
8
9
10
11
12
13
PART NUMBER
10843-003
10855-002
10855-003
10886-125
11013-004
11109
DESCRIPTION
T-Bolt Clamp, Range 4.88-5.5
Vinyl-Coated Loop Clamp, 1” ID
Vinyl-Coated Loop Clamp, 5/8” ID
HFB 5/16”-18 x 1-1/4” Gr 8
Power Module Asy DS150FR
Power Module Mount Kit
the locations of the mounting holes and drill (2)
Ø7/16” holes per mount.
Important: Locate the mounts such that the distance
between two mounts as wide as possible. Avoid
partially drilling through existing frame holes and
inside fuel line mounts.
3.
QTY
4
4
4
6
10
1
Verifying the mounts are held flush to the bottom of
the frame and utilizing the mount hole pattern, mark
20
4.
Attach the two mounts with 3/8” Flange Bolts and
Nuts. Torque to 35-43 ft-lbs. Note: Orientate nuts
outboard.
5.
Repeat with Volume Mounts on the passenger side of
the frame. Figure 55, in Appendix A: Drill
Locations, shows the suggested locations.
6.
Locate the Left Hand Volume Assembly.
DS150FR-S
10. Locate the Right Hand Volume Assembly.
WARNING: Each Volume Assembly is heavy (in excess of
100 lbs). Use of a portable lift, crane, or suitable jack is
recommended to support the Volume Assembly during
installation.
7.
11. Raise the volume assembly until the volume contacts
both mounts. Rotate the volume until the bleed
screws are located to the top and as vertical as
possible.
Raise the volume assembly until the volume contacts
both mounts. Rotate the volume assembly until the
bleed screws are located to the top and as vertical as
possible.
8.
Locate (2) T-Bolt Clamps, open the clamps, and
place them in the mounts around the two pegs.
9.
Secure both clamps around the volume and torque the
T-Bolt nut to 240 in-lbs.
12. Locate (2) T-Bolt Clamps, open the clamps, and
place them in the mounts around the two pegs.
13. Secure both clamps around the volume and torque the
T-Bolt nut to 240 in-lbs.
21
DS150FR-S
Power Module
ITEM
1
2
3
4
5
QTY
1
2
4
2
2
PART NUMBER
10799-015
10252-003
10012-011
10088-001
10510-002
DESCRIPTION
Power Module Manifold Mount
SFHS 3/8”-16 x 5/8” Gr 8
LFN 3/8”-16 Gr G
FW #10
STS #10-16 x 3/4” Hex Head
ITEM
6
7
8
9
10*
*P/N 10614-001 is included in the main kit.
22
QTY
1
2
4
2
1
PART NUMBER
10798-015
10805-007
10501-002
10322-021
10614-001
DESCRIPTION
Power Module Reservoir Mount
Grommet
HFB 3/8”-16 x 1-1/4” Gr 8
Hyd. Fit. 90, -4 37 x -4 37 F
Cap, Filler/Breather
DS150FR-S
1.
Locate the Power Module Assembly and the Power
Module Mounting Kit.
2.
Attach the Manifold Mount to the Power Module as
shown above using the 3/8”-16 x 5/8” Serrated
Flange Hex Screws. Torque to 39 ft-lbs.
3.
Insert the grommets into the Reservoir Mount and
attach it to the back of the plastic reservoir as shown
above using the #10 Flat Washers and #10-16 x 3/4”
Self Tapping Screws. Do not over tighten to where
the grommets deform.
4.
Attach the Power Module to the Cross-member
Channel as shown above using 3/8”-16 x 1-1/4” Hex
Flange Bolts and 3/8”-16 Locking Flange Nuts.
Torque to 39 ft-lbs.
5.
Remove the red plug from the top of the reservoir
and install the Filler/Breather Cap.
Hose Attachment and Routing [DS150FR-S]
Figure 15. DS150FR-A -4 Hose Routing (Top View)
Figure 16. DS150FR-A -10 Hose Routing (Bottom View)
1.
CAUTION: Attachment of the hydraulic hoses may result in
some spillage of fluid. Use of oil absorbent mats is
recommended.
23
Locate 3/16” ID PVC Tubing (not included with kit).
Note: Alternatively, a bleed kit similar to the Actron
7840 Bleed Kit can be used.
DS150FR-S
2.
Attach the PVC tubing to the bleed screw on the -10
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
11. Tighten all the -10 fittings to 36-63 ft-lbs.
12. Repeat with the opposite side.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
13. Attach the PVC tubing to the bleed screw on the -4
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
14. Open the bleed screw slightly to relieve any residual
pressure.
15. After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
Figure 17. Bleed screw locations.
3.
Open the bleed screw slightly to relieve any residual
pressure.
4.
After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
5.
Locate -10 hose and -10 JIC 90° Elbow Hydraulic
Fitting.
6.
Remove the cap from the elbow fitting on the strut.
7.
Loosely attach the elbow hose end (90° -10 JIC
fitting) to the strut port.
8.
Loosely attach the 90° elbow fitting to the opposite
end of the hose (with the straight -10 JIC fitting).
9.
Place a bucket or oil absorbent mat under the capped
end of the secondary volume.
16. Route the Left Hand (Driver side) -4 (1/4”) hydraulic
hose, attached to the volume assembly, to the Power
Module. Use of hose clamps is recommended to
secure the hose from movement or chafing.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
17. Remove the plug from the hose end.
18. Attach the hose end to the fitting in the port marked
“L”. Torque to 12 ft-lbs. Do not over tighten.
19. Repeat with the opposite side.
20. Attach the hose end to the fitting in the port marked
“R”. Torque to 12 ft-lbs. Do not over tighten.
21. Clean up any fluid spillage.
10. Remove the -10 cap from the volume and attach the 10 elbow.
24
DS150FR-S
Hose Attachment and Routing [DS150FR-SF]
ITEM
1
2
QTY
2
4
PART NUMBER
10012-010
10855-002
DESCRIPTION
LFN 5/16”-18 Gr G
Vinyl Coated Loop Clamp, 1”ID
ITEM
3
4
QTY
3
2
PART NUMBER
10855-003
10886-100
DESCRIPTION
Vinyl Coated Loop Clamp, 5/8” ID
HFB 5/16-18 x 1.000” Grade 8
CAUTION: Attachment of the hydraulic hoses may result in
some spillage of fluid. Use of oil absorbent mats is
recommended.
1.
Locate -10 hose on Left Hand (driver side)
Secondary Volume.
2.
Route hose to Left Hand strut area, as shown above.
3.
Locate 3/16” ID PVC Tubing (not included with kit).
Note: Alternatively, a bleed kit similar to the Actron
7840 Bleed Kit can be used.
4.
Figure 18. Bleed screw locations.
Attach the PVC tubing to the bleed screw on the -10
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
25
5.
Open the bleed screw slightly to relieve any residual
pressure.
6.
After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
7.
Remove the cap from the strut port.
DS150FR-S
8.
Raise the end of the -10 (5/8”) hose, attached to the
volume assembly, above the secondary volume to
prevent fluid loss.
9.
Remove the plug from the end of the hose.
10. Attach the hose end (-10 JIC fitting) to the strut port.
11. Torque to 36-63 ft-lbs.
12. Secure hose with clamps as shown above. Drill
attaching Ø3/8” holes as necessary.
13. Repeat with the opposite side.
Figure 20. Driver side and Passenger side -4 Hose routing.
19. Remove the plug from the hose end.
20. Attach the hose end to the fitting in the port marked
“L”. Torque to 12 ft-lbs. Do not over tighten.
21. Repeat with the opposite side.
22. Attach the hose end to the fitting in the port marked
“R”. Torque to 12 ft-lbs. Do not over tighten.
23. Clean up any fluid spillage.
Figure 19. Passenger Side -10 hose routing.
14. Use hose clamps to secure hoses from movement and
chafing.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
15. Attach the PVC tubing to the bleed screw on the -4
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
16. Open the bleed screw slightly to relieve any residual
pressure.
17. After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
18. Route the Left Hand (Driver side) -4 (1/4”) hydraulic
hose, attached to the volume assembly, to the Power
Module. Use of hose clamps is recommended to
secure the hose from movement or chafing.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
26
DS150FR-S
Hose Attachment and Routing [DS150FR-SS]
ITEM
1
2
QTY
10
4
PART NUMBER
10012-010
10855-002
DESCRIPTION
LFN 5/16”-18 Gr G
Vinyl Coated Loop Clamp, 1”ID
ITEM
3
4
QTY
6
10
PART NUMBER
10855-003
10886-100
DESCRIPTION
Vinyl Coated Loop Clamp, 5/8” ID
HFB 5/16-18 x 1.000” Grade 8
CAUTION: Attachment of the hydraulic hoses may result in
some spillage of fluid. Use of oil absorbent mats is
recommended.
1.
Locate -10 hose on Left Hand (driver side)
Secondary Volume.
2.
Route hose to strut area, over front hanger and axle.
3.
Locate 3/16” ID PVC Tubing (not included with kit).
Note: Alternatively, a bleed kit similar to the Actron
7840 Bleed Kit can be used.
4.
Figure 21. Bleed screw locations
Attach the PVC tubing to the bleed screw on the -10
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
27
5.
Open the bleed screw slightly to relieve any residual
pressure.
6.
After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
7.
Remove the cap from the strut port.
DS150FR-S
8.
Raise the end of the -10 (5/8”) hose, attached to the
volume assembly, above the secondary volume to
prevent fluid loss.
9.
Remove the plug from the end of the hose.
10. Attach the hose end (-10 JIC fitting) to the strut port.
11. Torque to 36-63 ft-lbs.
12. Secure hose with clamps as shown below. Drill
attaching Ø3/8” holes as necessary.
13. Repeat with the opposite side.
Figure 23. Driver side and Passenger side -4 Hose routing.
19. Remove the plug from the hose end.
20. Attach the hose end to the fitting in the port marked
“L”. Torque to 12 ft-lbs. Do not over tighten.
Figure 22. Driver Side -10 hose routing.
21. Repeat with the opposite side.
14. Use hose clamps to secure hoses from movement and
chafing.
22. Attach the hose end to the fitting in the port marked
“R”. Torque to 12 ft-lbs. Do not over tighten.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
23. Clean up any fluid spillage.
15. Attach the PVC tubing to the bleed screw on the -4
hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
16. Open the bleed screw slightly to relieve any residual
pressure.
17. After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
18. Route the Left Hand (Driver side) -4 (1/4”) hydraulic
hose, attached to the volume assembly, to the Power
Module. Use of hose clamps is recommended to
secure the hose from movement or chafing.
CAUTION: Make sure the hose is not chafing or in
contact with any sharp edges.
28
DS150FR-S
Height Sensors
ITEM
1
2
3
QTY
6
2
2
PART NUMBER
10012-010
10586-001
10587-006
DESCRIPTION
LFN 5/16-18 Gr G
Asy, Height Sensor
Asy, Linkage, 3.938” SS
ITEM
4
5
QTY
2
4
PART NUMBER
10591-003
10886-125
DESCRIPTION
Ball Stud, 5/16-18 x .75L
HFB 5/16-18 x 1.25 Gr 8
IMPORTANT: Strut assemblies must be installed
prior to the installation of the height sensors.
1.
Locate the Height Sensor, Linkage Assembly, and
Ball Stud.
2.
Attach the Ball Stud to the Left Hand (Driver Side)
Upper Control Arm, orientated with the ball pointing
inboard, using the 5/16”-18 Locking Flange Nut.
Torque to 14-17 ft-lbs.
3.
Attach the Height Sensor to the Left Hand (Driver
Side) Hanger using the 5/16”-18 x 1” Hex Flange
Bolt and 5/16”-18 Locking Flange Nut. Torque to
14-17 ft-lbs. Do not over torque.
4.
Figure 24. Height Sensor Linkage Installation.
Snap the Linkage Assembly to the ball stud attached
to the lower control arm and to the ball stud on the
Height Sensor arm. Install rod end locks as shown.
5.
29
Repeat with the Right Hand (Passenger Side).
DS150FR-S
Steering Sensors
ITEM
1
2
3
4
QTY
1
4
1
1
PART NUMBER
10001-005
10012-010
10012-012
10586-001
DESCRIPTION
HB 3/4”-16x4-1/2” Gr 8
LFN 5/16”-18 Gr G
LFN 3/4”-16 Gr G
Height /Steering Sensor
ITEM
5
6
7
8
Note: Steering sensor and height sensors are the same part
number.
1.
Remove the hex bolt, lock nut, and washer from the
pitman arm.
2.
Install the Steering Linkage Mount using the
provided 3/4”-16 x 4-1/2” Hex Bolt and Locking
Flange Nut. Torque to 215-245 ft-lbs. Note: If
OEM bolt is 7/8”, reuse bolt and nut in place of
provided 3/4” bolt and nut.
QTY
1
1
1
4
3.
PART NUMBER
10587-006
10733-004
10741-002
10886-125
DESCRIPTION
Asy, Linkage 3.938” SS
Steering Linkage Mount
Steering Sensor Mount
HFB 5/16”-18 x 1-1/4” Gr8
Remove the bolt attaching the filter mount to the
frame, as shown in Error! Reference source not
found.6 Retain bolt and nut for reuse.
Figure 26. Steering Sensor Mount Installation.
Figure 25. Steering Linkage Mount installation.
30
4.
Install the Steering Sensor Bracket reusing the OEM
fasteners and the 5/16”-18 fasteners as shown in
Figure 27.
5.
Torque the OEM fastener to 90 ft-lbs.
6.
Torque the 5/16”-18 fasteners to 14-17 ft-lbs.
DS150FR-S
Figure 29. Sensor Linkage Installation.
Figure 27. Installation of Steering Sensor Mount.
7.
Install the Steering Sensor as shown in Figure 28
using the 5/16” fasteners.
8.
Torque to 14-17 ft-lbs.
Figure 28. Steering Sensor Installation.
9.
Snap the Linkage Assembly to the ball stud attached
to the lower control arm and to the ball stud on the
Sensor arm. Install rod end locks as shown.
31
DS150FR-S
Wiring
1.
Locate the External Electrical Harness attached to the
power module.
2.
Unroll the wiring harness and use the Electrical
Schematics wiring diagram to identify the connection
ends.
3.
Locate the trunk containing the Height Sensor (J21
and J22) and the Rate Valve (J23 and J24)
connections.
4.
Route the trunk towards the height sensors and rate
valves. Note: The power module is mounted behind
the axle, but ahead of the volumes, therefore the
trunk may need to be routed first towards the height
sensors, and then back towards the rate valves.
5.
Connect the height sensor and rate valve connections.
6.
Secure the harness to OEM harness on the driver
side. Use of plastic clips is recommended.
7.
Locate the Black 8ga. wire ground ring terminal, J30,
branch near the power module.
8.
Locate and drill Ø1/4” hole in frame. Remove frame
coating(s) as needed to ensure metal-to-metal contact
between the ring terminal and frame.
9.
Attach the ground ring terminal, J30, to the chassis
frame for grounding. Sealant should be applied after
ring terminal is secured.
10. Route the remaining trunk (containing the blunt wires
and steering sensor blunt wires) towards the cab.
Secure to OEM wiring harness.
11. Locate the Dash Harnes.
12. Inside the cab, under the dash, locate the firewall
rubber pass through grommets.
Figure 30. DS150FR-S Sensor connections.
Figure 31. DS150FR-SF Sensor connections.
Figure 33. Firewall pass through.
13. Punch out two holes for the two dash harness
branches.
14. Push the dash harness branch labeled “Vehicle
Connections” and the branch labeled “External
Harness” through the firewall pass through.
15. Attach the Ground Ring Terminal, J32, from the dash
harness to the firewall ground post.
Figure 32. DS150FR-SS Sensor connections
32
DS150FR-S
Figure 34. Under dash ground connections.
16. Secure the dash harness.
17. Locate the following Vehicle Electrical
Modules/Connectors (refer to Freightliner Body
Builder Reference Guide OBD 2013/GHG 14
Electrical):
Figure 35. ATC Fuse Output connector..
Connector:
PNDB (Power Net
Distribution Box)
TIC (Transmission
Interface Connector)
Location:
Under hood, on firewall,
driver side.
Multiple possible locations:
*Under hood, on firewall,
driver side (34C-001),
*Under Cab (34C-002), or
*End of Frame (34C-003)
BBLI (Body Builder Multiple possible locations:
Lighting Interface)
*Back of cab (353-022)
*End of frame (353-023)
*Back of cab w/PDM
(353-026)
*End of frame w/PDM
(353-027)
Maybe under cab on crew cab
versions.
Depending on the location of these connectors and
the configuration of the vehicle, extra length of wire
may need to be spliced in.
19. Pull out, but do not remove the TPA.
Figure 36. Resetting the TPA.
20. Locate the red “BAT” wire from the dash harness in
the bundle labeled “Vehicle Connections”.
21. Attach an APEX 2.8mm Female terminal to the wire.
See
Also see Appendix B: Electrical Terminals.
18. At the PNBD, disconnect the ATC Fuse Output
connector.
33
DS150FR-S
22. Appendix B: Electrical Terminals.
23. Remove the plug from the “D” or pin 4 location.
Figure 40. Unlocking the connector.
30. Attach an APEX 1.5mm male terminal to both the
Yellow (Ignition) wire from the dash harness (located
in the branch labeled “Vehicle Connections”) and the
Violet/White (Speed) wire from the main electrical
harness. Splice additional wire to either wire if
necessary to reach the Transmission Interface
Connector.
Figure 37. Inserting the BAT power wire.
24. Insert the wire into the “D” or pin 4 position of the
connector.
31. Remove plugs from pin 1 and pin 5.
32. Insert the Violet/White wire into Pin 5 of the
connector.
Figure 38. TPA in lock position.
25. Press the TPA back into the lock position.
26. Reconnect the connector to the PNBD.
27. Locate the Transmission Interface Connector.
Figure 41. Inserting Violet/White wire.
33. Insert the Yellow wire into Pin 1 of the connector.
34. Push and lock the TPA.
Figure 39. Transmission Interface Connector when
located under hood.
28. Unplug the connector.
Figure 42. Locking the TPA.
29. Pull out, but do not remove the white TPA.
35. Reconnect the connector.
36. Secure the wires.
34
DS150FR-S
37. Locate the Body Builder Lightning Interface. The
connector should have an orange ribbon tape within
2” for identification.
38. Inside the main suspension harness, locate the
Pink/Black wire. Pull wire from loom and rewrap
junction with electrical tape.
39. Disconnect the connector.
40. Pull out, but do not remove the red TPA.
Figure 45. Body Builder Lighting Interface connector with
TPA locked in position.
45. Reconnect the Body Builder Lighting Interface
connector.
46. Secure all wiring.
47. Locate the remaining Dash harness wires labeled
“External Harness”:
Red (Battery Power)
Yellow (Ignition)
White (CAN-H)
White/Black (CAN-L)
Black (Ground)
Yellow/Black (Park)
Figure 43. Unlocking the connector.
41. Attach an APEX 2.8mm male terminal to the
Pink/Black (Brake) wire.
42. Remove the plug from pin 4.
43. Insert the Pink/Black wire into Pin 4.
48. Crimp each wire to the corresponding blunt wire in
the External Harness. Match wire colors, crimp
using butt splices, and install heat shrink.
49. Secure all wires.
50. Locate the branch containing connector J35.
51. Route branch to the steering sensor and connect. If
necessary splice additional length to the three wires.
Make sure the correct connections are made.
Figure 44. Inserting Pink/Black wire.
44. Press and lock the TPA.
Figure 46. Steering Sensor electrical connection.
35
DS150FR-S
52. Secure the harness.
closed (NC) door switch which remains open
when the door is closed (or closed when the door
is opened). One side of the switch must be
connected to a ground source and the other side
routed to the door harness. If multiple switches
are used, they should be wired in a parallel
arrangement with the door harness. Requires
single wire routed from source to door harness.
53. Locate the Red 8ga battery connection branch.
54. Route branch to the auxiliary battery positive
terminal.
55. Locate the Battery Fuse Lead containing the 80 amp
fuse.
56. Remove the 80 amp fuse.
B: Dual Wire – Ground Signal From System
57. Crimp the fuse lead to the 8ga battery connection
branch blunt end.
Ground is provided by the suspension system
when the Brown (W93) wire is connected to the
Tan/Black (W98) wire of the door harness. This
arrangement requires a remote switch that is a
normally closed (NC) door switch which remains
open when the door is closed (or closed when the
door is opened). One side of the switch needs to
be connected to the door harness Brown (W93)
wire and the other side to the door harness
Tan/Black (W98) wire. Requires two wires
routed from switch to door harness.
58. Melt the heat shrink on the crimped connection to
seal the splice.
59. Connect to the positive terminal post.
60. Replace the 80 amp fuse.
Optional Door Electrical Harness Installation:
The optional door harness can be used to remotely activate the
system “kneeling” feature in which the suspension
automatically lowers to a point slightly less than maximum
jounce travel. The door harness can be utilized in two
actuation methods.
IMPORTANT: Do not connect positive (12VDC) signal to
either the W98 Tan/Blk or W93 Brown wires. Applying
positive (12VDC) to either of these wires can result in ECU
failure.
A. Single Wire - Ground Signal From Source
Ground is provided to the door harness Brown
(W93) wire from a grounding source (e.g.
multiplex signal, switch, etc.). If a remote switch
is used, it is recommended to use a normally
36
1.
Door harness wires are located on the main external
wiring harness as a branch near the power module.
2.
Unwrap the door harness wires.
3.
Based on the selected actuation method above, strip
the end(s) of the door harness blunt wire(s) and
connect the end(s) to the signal source using a heat
shrinkable butt-splice. Crimp the connection(s)
accordingly and apply heat to the insulator to seal the
connection(s).
DS150FR-S
System Preparation
Initial System Fill
1. Install the wheels and tires. Torque wheel nuts to
OEM specifications.
2.
Verify that the front wheels are steered straight
ahead.
3.
Lower the vehicle to the ground and remove any jack
stands from under the vehicle. The suspension
should be in the kneeled position.
4.
Locate the container of Silicone Fluid.
5.
Remove the breather cap from the Power Module
reservoir.
6.
Fill the reservoir approximately 2/3 full.
7.
Turn the ignition key to “Run” and ensure that the
LiquidSpring driver display LEDs light up and that
the red “Warning” LED is not lit. If the red
“Warning” LED is lit, proceed to the Trouble
Shooting Section.
c.
13. After the suspension system stops leveling, check the
fluid level in the reservoir. If low, fill to the
indicated line.
Figure 47. Final fill fluid level.
Bleeding the System
1. Verify system is turned OFF by either pressing the
ON/OFF button on the driver interface until the lights
are turned off or turning the ignition off.
WARNING: Do not run vehicle in an enclosed
building without adequate ventilation or without
ducting exhaust fumes outside. Operation of a vehicle
inside an enclosed building can lead to serious injury
or death.
8.
Press and release the Red ON/OFF button on the
driver display. All LEDs on the driver display should
go out.
9.
Press and release the Red ON/OFF button again. The
LEDs on the driver display should all flash and then
only the four yellow arrow LEDs, one green ride
mode indicator LED, and one green ride height
indicator LED should remain lit.
Completely depressurize the system. See
Depressurizing the System section, under System
Operation
2.
Locate 3/16” ID PVC Tubing (not included with kit).
Note: Alternatively, a bleed kit similar to the Actron
7840 Bleed Kit can be used.
3.
Attach the PVC tubing to one of the upper bleed
screws on the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
10. The green ride height indicator LED should indicate
“Low” and begin flashing as the pump/motor starts.
If pump/motor does not start, check Trouble Shooting
Electrical Section.
Figure 48. Bleed screw locations.
11. Monitor the fluid level in the reservoir. If the level
drops below 1/4 of the tank, press and release the Red
ON/OFF button to shut off the system, refill the
reservoir, and turn the system back on by pressing the
Red ON/OFF button.
12. If the suspension system does not begin to rise to a
preset ride height after 3 minutes, stop the system and
check the following first and then repeat this step:
a.
Check for any fluid leaks.
b.
Check that the hoses are properly connected.
4.
Open the bleed screw slightly.
5.
After air bubbles are no longer present, close the
bleed screw and torque to 13-18 ft-lbs.
6.
Repeat with remaining bleed screws. Note: the
system may need to powered on and allowed to repressurize .
7.
Repeat with other side.
Calibrating the System
IMPORTANT: Proper calibration of the system must be
conducted with the vehicle loaded to the as delivered
37
DS150FR-S
Post Installation Welding
condition with body installed. For calibration on an empty
chassis cab, LiquidSpring recommends weight be added to
the frame approximately equal to the planned body to
allow for proper bushing deflections.
WARNING: Prior to any chassis welding conducted after
the installation of the LiquidSpring suspension system,
disconnect cables from battery, disconnect ECU Header
connectors (see below), and Power Module ground
connection (see below).
Note: The LiquidSpring Calibration routine will automatically
determine maximum and minimum suspension ride height.
Based on those ride heights, the system will determine the
correct normal design ride height. The calibration system will
also calibrate the steering sensor.
1.
Verify that the front wheels are steered straight
ahead.
2.
Lower the vehicle to the ground and remove any jack
stands and any other obstructions from under the
vehicle.
3.
To begin the calibration, turn the ignition key to
“Run” and ensure that the LiquidSpring driver
display lights up and that the red Error light is not
blinking.
WARNING: Do not run vehicle in an enclosed building
without adequate ventilation or without ducting exhaust
fumes outside. Operation of a vehicle inside an enclosed
building can lead to serious injury or death.
4.
Press and release the Red ON/OFF button on the
driver display. All lights on the driver display should
go out.
5.
Press and release the Red ON/OFF button a second
time. The lights on the driver display should all flash
then only show the four yellow arrow lights, one
green ride mode indicator, and one green ride height
indicator.
6.
Press and hold both Ride Height Adjustment Buttons
simultaneously until the SPORT, COMFORT, HIGH,
and LOW green LED’s begin to flash. The
suspension system will begin to rise to the full high
position, and then lower to the full lowered position.
7.
After the system completes the calibration routine,
the suspension will return to the original ride height.
8.
Turn off the ignition for at least 3 minutes. Note:
The suspension system will not use the calibrated
ride height settings until power has been cycled.
Figure 49. ECU disconnects prior to welding on chassis.
Note: Pressing the red ON/OFF button on the driver
display does not cycle power to the LiquidSpring
suspension system, but only will enable/disable the
system.
9.
Turn the ignition back to Run, then press the Red
ON/OFF button twice and verify the suspension
system moves to the new and correct ride height.
10. Calibration is now completed.
38
DS150FR-S
System Operation
System Start Up:

In most instances, the suspension system can be left
alone to operate automatically.

After startup, all the indicator lights will flash on for
1-2 seconds, and then the Green Ride Height
Indication LED and Green Ride Mode Indication
LED will light to show the current Ride Mode and
Ride Height.


Warning Light:
If the Red LED warning light is continuously illuminated
along with one or more of the other indicator lights,
please refer to the Troubleshooting Section on page 42.
Ride Mode Adjustment:
Press the UP/DOWN arrow buttons to change the ride
mode between SPORT, NORMAL, and COMFORT. The
Green indicator light will show the set mode.

The four Yellow Steering Centering Indication
LED’s will light up when the front wheels are
pointed straight ahead and the steering wheel is
centered. If the yellow lights are not lit when the
steering is straight, the system has lost centering and
must be corrected. See section Calibrating Steering
Sensor.


When the steering wheel is turned more than 20° off
center, the four Yellow Steering Centering Indication
LED will not be lit.
Comfort Mode provides a smooth, soft ride. Use for
normal city and highway driving.
Sport Mode provides more “feel” or response to the
road conditions. Use where road conditions or
personal preference demand more control.
Normal Mode is a balance between Comfort and
Sport. Use where more control than Comfort is
desired, but better ride than Sport.
The setting can be changed at any time. Based on road
conditions, steering wheel angle, and the vehicle speed,
the system automatically adjusts to provide the best
handling while providing a smooth ride. All three settings
will feel similar on a smooth road.
ON/OFF Button:
Pressing the ON/OFF button will enable/disable the
suspension. When the suspension is ON, relevant LED’s
are lit up. When the suspension is OFF, none of the
LED’s are lit. It is recommended to leave the suspension
ON at all times unless the vehicle or suspension is being
serviced.
Ride Height Adjustment:
Press the UP/DOWN arrow buttons to change ride height
from NORMAL to HIGH (body up) or LOW (body
down).

IMPORTANT: After turning the vehicle ignition off,
the suspension system will remain powered for 2-1/2
minutes before shutting off.
39
A solid green LED will indicate the selected
height. A flashing green LED will indicate the
current height and that height adjustment is
occurring. When a single solid green LED is lit,
the selected height has been achieved.
DS150FR-S






Depressurizing the System
1. Turn the ignition key to “Run” and ensure that the
LiquidSpring driver display LEDs light up and that
the red “Warning” LED is not lit. If the red
“Warning” LED is lit, proceed to the Trouble
Shooting Section.
Two solid green LEDs will be lit if the current
height is not the selected height and height
adjustment is not occurring.
If LOW or HIGH heights are selected while the
vehicle is traveling at less than 10 mph or
stopped, the suspension height is either lowered
or raised.
If LOW or HIGH heights are selected while the
vehicle is traveling at greater than 10 mph, the
suspension will ignore the selected height and
remain in NORMAL height unless the vehicle
speed goes below 10 mph within 2 minutes of
selecting the height. In this instance, the
NORMAL height green LED will flash and the
selected height green LED will be lit solid until
the speed goes below 10 mph within 2 minutes
of selecting the height. If the vehicle speed
doesn’t go below 10mph within the 2 minute
period, the suspension will remain in NORMAL
height indicated by only the NORMAL height
green LED lit solid.
If LOW height is selected and the ignition is
turned off before LOW height is achieved, the
system will continue to lower to LOW height.
When LOW height is selected the system will
monitor and maintain the kneeled position by
only lowering as needed for 4 hours after the
ignition is turned off.
If HIGH height is selected and the ignition is
turned off before HIGH height is achieved, the
system will stop adjusting ride height. When
HIGH height is selected the system will monitor
and maintain the current position by only
lowering as needed for 4 hours after the ignition
is turned off.
The door switch function (if equipped) is
disabled when the driver display LOW or HIGH
height is selected before the door is opened on
vehicles equipped with a door switch for
kneeling.
WARNING: Do not run vehicle in an enclosed
building without adequate ventilation or without
ducting exhaust fumes outside. Operation of a vehicle
inside an enclosed building can lead to serious injury
or death.
1.
Press and release the Red ON/OFF button on the
driver display. All LEDs on the driver display should
go out.
2.
Press and release the Red ON/OFF button again. The
LEDs on the driver display should all flash and then
only the four yellow arrow LEDs, one green ride
mode indicator LED, and one green ride height
indicator LED should remain lit.
3.
Press and release the HEIGHT DOWN arrow button
to lower the vehicle to the LOW height.
4.
Press and hold the HEIGHT DOWN arrow button for
approximately 2 minutes.
5.
Release the HEIGHT DOWN arrow button.
6.
Press and release the ON/OFF button to disable the
system.
7.
Turn off the vehicle ignition.
If any of the hydraulic connected components is to be
removed and serviced, it is recommended to also follow
the following steps:
IMPORTANT: While parked for an extended time
with the vehicle and/or suspension system turned off,
suspension ride will change with temperature change.
Increases in ambient temperature or parking in direct
sunlight can cause the suspension ride height to
increase. As temperature lowers, the suspension ride
height can decrease.
8.
Locate 3/16” ID PVC Tubing. Note: Alternatively, a
bleed kit similar to the Actron 7840 Bleed Kit can be
used.
9.
Attach the PVC tubing to one of the upper bleed
screws on the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
Figure 50. Bleed screw locations.
10. Open the bleed screw slightly to relieve any residual
pressure.
40
DS150FR-S
11. After pressure is relieved, close the bleed screw and
torque to 13-18 ft-lbs.
Notes:

Jacking up the chassis of a lowered, depressurized
chassis will cause a slight vacuum in the system and
minimize fluid loss while disconnecting hoses.

For service of non-hydraulic connected suspension
components, the suspension system can be first raised
to the HIGH height, appropriate jack stands placed
under the chassis, then depressurized as listed above
lowering the chassis onto the jack stands.
Calibrating the Steering Sensor Only
IMPORTANT: The LiquidSpring CLASS® system
includes an automatic self-centering routine. In conditions
such as driving on highway with significant side wind, the
yellow lights may temporarily not be lit when the steering
wheel is exactly centered. Rotate slowly from center to full
steering stop, then repeat the opposite direction. If the
yellow lights are lit during the travel, the system is
operating normally and the steering sensor does not need
to be manually re-centered. Continue operating normally.
If the yellow lights do not light up at all during turning the
steering wheel, following the instructions below.
1.
Verify that the front wheels are steered straight
ahead.
2.
To begin the calibration, turn the ignition key to
“Run” and ensure that the LiquidSpring driver
display lights up and that the red “Warning” LED is
not lit or flashing.
WARNING: Do not run vehicle in an enclosed building
without adequate ventilation or without ducting exhaust
fumes outside. Operation of a vehicle inside an enclosed
building can lead to serious injury or death.
3.
Press and release the Red ON/OFF button on the
driver display. All LEDs on the driver display should
go out.
4.
Press and release the Red ON/OFF button again. The
LEDs on the driver display should all flash and then
only the four yellow arrow LEDs, one green ride
mode indicator LED, and one green ride height
indicator LED should remain lit.
5.
Press and hold both Ride Height Adjustment Buttons
simultaneously until the SPORT, COMFORT, HIGH,
and LOW green LED’s begin to flash.
6.
As soon as the four green LED’s begin to flash, press
the ON/OFF button to stop the process.
7.
Verify that the four yellow arrow LED’s are lit.
8.
Steering calibration is completed.
41
DS150FR-S
Troubleshooting
The LiquidSpring CLASS® system includes on-board diagnostics to assist in pin-pointing potential issues. When a fault in the system
occurs, the red warning light on the Drivers Interface will light along with one or more of the other lights on the interface.
Driver Interface
Lights
Condition
Warning +
RIDE: SPORT
Battery Voltage in
excess of 16VDC
Warning +
RIDE: NORMAL
Warning +
RIDE: COMFORT
Pump Motor runs in
excess of 3 minutes
Warning +
HEIGHT: HIGH
Warning +
HEIGHT: NORMAL
Issue with Right Hand
Height Sensor
System kneels in excess
of 3 minutes without
suspension movement
Issue with Left Hand
Height Sensor
Driver Interface cannot
communicate with ECU.
Warning +
HEIGHT: LOW
Slow or Fast Blinking
Warning Light
Battery Voltage below 9
VDC
Cause
Correction
Vehicle charging system providing incorrect voltage.
LiquidSpring system not connected to 12VDC
electrical system
See Issues with Vehicle Raising/Pump Section
Inspect and replace as necessary.
Inspect and replace as necessary
Vehicle charging system providing incorrect voltage
Low vehicle battery
See Issues with Height Sensors Section
Inspect and replace as necessary
Inspect and replace as necessary
See Issues with Height Sensors Section
See Issues with Vehicle Lowering/Dump Valve
Section
See Issues with Vehicle Lowering/Dump Valve
Section
See Issues with Height Sensors Section
See Issues with Height Sensors Section
See Issues with Driver Interface
See Issues with Driver Interface
See Issues with Vehicle Raising/Pump Section
Issues with Vehicle Raising/Pump
Condition
Vehicle Leveled, Pump continues to run
Vehicle Not Leveled (or Raised), Pump
runs
Vehicle Not Leveled (or Raised), Pump
does not run
Pump runs for short time then stops
Pump runs intermittently
Cause
Correction
Pump motor shorted out.
Software issue
Excessive noise in height sensor
Reservoir fluid level low
Hydraulic leak in system
Vehicle overloaded
Air in pump
Contact LiquidSpring for further instructions.
Turn off ignition, wait 30 seconds, restart vehicle.
See Issues with Height Sensors
Fill reservoir to specified level.
Check for fluid leaks and repair or replace.
Check vehicle loading and correct.
Check fluid level in reservoir and fill accordingly. Fully depressurize
system and restart leveling.
Replace power module.
See Issues with Height Sensors
Turn system on.
Check system fuses
Check wiring between power module and battery.
Contact LiquidSpring for further instructions.
Check wiring harness connections and battery connections. Repair as
necessary.
Internal leak in power module
Height sensor error
System not turned on.
Blown fuse
Loss of electrical power
Motor controller over temperature
Loose connector or wiring
Issues with Vehicle Lowering/Dump Valve
Condition
Vehicle does not lower (kneel).
Vehicle slow lowering (kneeling)
Cause
Correction
System not turned on
Blown fuse
Obstacle under vehicle frame
Wiring harness disconnected
Loss of electrical power
Power module filters plugged
Internal power module blockage
Partial internal power module blockage
42
Turn system on
Check system fuses and replace as necessary
Remove obstacle
Check wiring harness connections and reconnect
Check wiring between power module and battery
Contact LiquidSpring for further instructions
Contact LiquidSpring for further instructions
Contact LiquidSpring for further instructions
DS150FR-S
Issues with One Corner Not Leveling Properly
Condition
One side will not raise or lower
One corner raises and lowers slower than
other corners
Cause
Correction
Internal power module blockage
Low voltage
Wiring harness disconnected
Obstacle under vehicle frame
Power module filters plugged
Height sensor error
Internal power module blockage
Filter partially clogged
Contact LiquidSpring for further instructions
Check battery voltage.
Check wiring harness connections and reconnect
Remove obstacle
Contact LiquidSpring for further instructions
See Issues with Height Sensors
Contact LiquidSpring for further instructions
Contact LiquidSpring for further instructions
Issues with Height Sensors
Condition
Vehicle or corner stops leveling at
incorrect height
Corner height where leveling stops is
inconsistent
Vehicle will not level - no height sensor
signal
No Height Sensor Signal change while
driving
Cause
Correction
Damaged height sensor and/or linkage
Incorrect calibration
Incorrect height sensor installation
Sensor or Linkage loose
Loose connector / wire
Height Sensor wiring shorted, broken, or
disconnected
Malfunction in Sensor
Linkage broken/disconnected
Inspect height sensor components. Replace as necessary.
Recalibrate vehicle – see System Operation section.
Inspect height sensor components and correct.
Inspect installation of height sensor and linkages and tighten if necessary
Inspect wiring between sensor and power module for loose connection
Inspect wiring between sensor and power module.
Replace sensor.
Inspect installation of height sensor and linkages. Correct and/or replace.
Issues with Ride/Handling
Condition
Vehicle rolls side to side excessively
Excessive stiffness when on flat, straight
road
Cause
Correction
System inactive (Drivers interface dark)
No electrical power to system
Strut bushings worn
Control arm bushings worn
Sway bar bushings worn
Strut mounting loose
Rate Valve wiring shorted, broken, or
disconnected
Voltage to Rate Valve solenoid too low
Rate Valve Poppet Jammed open
No vehicle speed signal
Short to Rate Valve
Wiring to Rate Valve incorrect
Turn system on (press On/Off button)
Inspect and replace as necessary
Inspect and replace as necessary
Inspect and replace as necessary
Inspect and replace as necessary
Inspect and replace as necessary
Inspect wiring and correct/replace as necessary.
Check battery voltage.
Contact LiquidSpring for further instructions
See Issues with Vehicle Speed Signal section.
Check wiring between rate valve (on secondary volume) and power
module for signs of shorts. Replace as necessary.
Inspect wiring and correct as necessary
Issues with Steering Sensor
Condition
No steering signal ( reduced roll control
when cornering)
Yellow lights on driver display not lit
when steered straight ahead.
Intermittent steering sensor signal
Cause
Correction
Steering sensor wiring broke or
incorrect.
Steering sensor malfunction
Steering sensor not installed correctly
Zero point of steering sensor incorrect.
Inspect wiring to steering sensor and correct as necessary.
Loose connector / wire
Check wiring between Steering sensor and Power module for loose
connection.
43
Replace sensor
Inspect installation and correct as necessary
See Calibrating the Steering Sensor Only.
DS150FR-S
Issues with Vehicle Speed Signal
Condition
System leveling excessively while
driving.
Intermittent speed sensor signal
Cause
Correction
Speed Sensor wiring shorted, broken, or
disconnected
Speed signal malfunction
Loose connector / wire
Inspect wiring and repair/replace as necessary
Replace OEM speed sensor. See OEM service manual.
Check wiring between Speed sensor and Power module for loose
connection.
Issues with Vehicle Brake Signal
Condition
Vehicle will not level
Intermittent leveling
Cause
Correction
Brake signal wire not correctly tapped.
Brake switch malfunction
Loose connector / wire
Inspect wiring and repair/replace as necessary.
Replace OEM speed sensor. See OEM service manual.
Inspect wiring and repair/replace as necessary.
Issues with Door Switch
Condition
Vehicle will not kneel when rear door
opened
Vehicle kneels whenever speed below
5mph
Intermittent door switch signal
Cause
Correction
Short or break in wiring between door
switch and power module.
Door switch malfunction
Short or break in wiring between door
switch and power module.
Door Switch out of adjustment
Door switch malfunction
Loose connector / wire
Inspect wiring and repair/replace as necessary.
Inspect door switch and repair/replace as necessary
Inspect wiring and repair/replace as necessary.
Check installation of door switch and adjust as necessary
Inspect and replace per body builder instructions.
Inspect wiring and repair/replace as necessary.
Issues with Vehicle Ignition Signal
Condition
System does not turn on (no leveling or
stiffness control)
System does not turn off once ignition
switched off
System intermittently works
Cause
Correction
No ignition signal to controller or driver
interface
Ignition "sensor" malfunction
Signal side short to battery
Ignition "sensor" malfunction
Loose connector / wire
Inspect wiring and repair/replace as necessary.
Inspect and replace per OEM service manual.
Inspect wiring and repair/replace as necessary.
Inspect and replace per OEM service manual.
Inspect wiring and repair/replace as necessary.
Issues with Vehicle Park Signal
Condition
System will start up but won't level when
parked
System levels when stopped and not in
park
Intermittent leveling when stopped in or
out of park
Cause
Correction
No park signal to controller
Park sensor malfunction
Park signal always on
Park sensor malfunction
Loose connector / wire
Inspect wiring and repair/replace as necessary.
Inspect and replace per OEM service manual.
Inspect wiring and repair/replace as necessary.
Inspect and replace per OEM service manual.
Inspect wiring and repair/replace as necessary.
Issues with Driver Interface
Condition
Warning light blinks, system appears to
level.
Warning light blinks, system does not
appear to operate (level)
Cause
Correction
CAN wires crossed or not connected.
Malfunctioning Driver Interface
No power to ECU (5A 18ga Red Wire)
No ignition signal to ECU (Yellow Wire)
CAN wires crossed or not connected.
44
Inspect wiring and repair/replace as necessary.
Inspect and replace as necessary.
Inspect wiring and repair/replace as necessary.
Inspect wiring and repair/replace as necessary.
Inspect wiring and repair/replace as necessary.
DS150FR-S
Issues with Power Module
Condition
Cause
Correction
Pump exhibits high pitch whine
immediately after pump stops or when
vehicle lowering
The Check Valve is stuck open
Replace Power Module
Pump running under heavy load and
leveling slow
Pump running under heavy load and no
leveling
The Check Valve is only partially open
Replace Power Module
The Check valve is stuck closed
Replace Power Module
Hydraulic fluid leaking from Power
Module
O-ring failure
Manifold cracked
Fitting loose
Valve loose
Bolts between manifolds loose/broken
Hydraulic line loose
Bolts between reservoir and manifold
loose/broken
Broken / cracked reservoir
Replace O-ring
Replace Power Module
Tighten fittings
Tighten valves to correct torque
Replace and /or tighten bolts to correct torque
Tighten hydraulic line correctly
Replace and/or tighten bolts to required torque
Replace reservoir
Issues with Strut Assembly
Condition
Hydraulic Leak
Rod broken at bushing housing
Rod doesn't move freely in/out cylinder
Rod moves very easily in/out cylinder
Reduced damping level
Strut upper mount not securely attached
to frame or Strut
Strut lower mount not securely attached
to axle or strut
Cause
Correction
Weld failure between cylinder and end
Cylinder fracture
Threads stripped between cylinder and
gland
Seals worn out
Rod severely scratched or dented
Fitting loose
Hose failure
Hose cut
Weld failure
Piston jammed in cylinder
Piston broken therefore no damping
Damping components broken/worn out
Bolts attaching bracket to frame broken /
came out
Bolt attaching strut to bracket broke /
came out
Weld Failure
Structural failure
Bolts attaching bracket to axle broken /
came out
Bolt attaching strut to bracket broke /
came out
Weld Failure
Structural failure
45
Replace strut
Replace strut
Replace strut
Replace strut
Replace strut
Tighten or replace fittings
Replace failed hose
Replace failed hose
Replace strut
Replace strut
Replace strut
Replace strut
Replace bolts and tighten to required torque
Replace bolts and tighten to required torque
Replace strut upper mount
Replace strut upper mount
Replace bolts and tighten to required torque
Replace bolts and tighten to required torque
Replace strut lower mount
Replace strut lower mount
DS150FR-S
Issues with Secondary Volume Assembly
Condition
Hydraulic Leak
loose or no longer attached
Cause
Correction
Weld failure between tube and end
Weld failure between tube and manifold
Cylinder fracture
Bleed screw loose
Fitting loose
Hose failure
Hose cut
Bolts attaching bracket to frame broken /
came out
Bolt attaching volumes to bracket broke /
came out
Weld Failure
Structural failure
46
Replace secondary volume welded assembly
Replace secondary volume welded assembly
Replace secondary volume welded assembly
Tighten bleed screws to appropriate torque
Tighten all fittings
Replace failed hose
Replace failed hose
Replace bolts and tighten to required torque
Replace bolts and tighten to required torque
Replace brackets
Replace brackets
DS150FR-S
Part Identification:
DS150FR-S
47
DS150FR-S
DS150FR-S
ITEM
QTY
PART NUMBER
DESCRIPTION
ITEM
QTY
PART NUMBER
1
1
10001-005
HCS 3/4-16 x 4-1/2 Gr 8
32
1
10795-011
Mount, Cross member, RH
2
2
10002-550
HCS 7/8”-9 x 5-1/2” Gr 8
33
1
10796-007
Cross member Channel
3
2
10003-003
HCS 1”-8 x 6”, Gr. 8
34
2
10810-014
Asy, Hose, -10 x 18-13/16" L
4
2
10003-004
HCS 1”-8 x 6-1/2” Gr. 8
35
1
10811-011
Mount Template, Detroit Axle
5
2
10006-003
HFW 7/8”
36
1
10811-012
Mount Template, Meritor Axle
6
4
10006-004
HFW 1”
37
1
10811-014
Frame Drilling Template
7
4
10012-003
LFN 1”-8, Gr G Top Lock
38
1
10815-001
Wiring Harness, Fused Battery
Lead
8
16
10012-007
LFN 1/2”-13, Gr. G
39
4
10830-017
Volume Mount
9
28
10012-008
LFN 5/8”-11 Gr G
40
4
10843-003
T-Bolt Clamp, Range 4.88-5.5
10
14
10012-010
LFN 5/16”-18, Gr. G
41
4
10855-003
Vinyl-Coated Loop Clamp, 5/8" ID
11
9
10012-012
LFN 3/4”-16, Gr. G
42
2
10867-003
Jounce Bumper, 2.375"Dia x 3.00"T
12
4
10012-014
LFN 3/4”-10 Gr G
43
24
10874-200
HFB 5/8-11x2.000, Gr. 8
13
2
10012-017
LFN 7/8”-9, Gr G
44
2
10874-375
HFB 5/8-11x3.750, Gr. 8
14
4
10064-005
U-Bolt 3/4-16 x 9.03 Tri-8
45
2
10874-600
HFB 5/8-11 x 6", Gr. 8
15
2
10322-010
Hyd Fit 90, -10 37 x -10 37 F
46
16
10885-150
HFB 1/2-13x1.500, Gr. 8
16
2
10474-001
Silicone Oil, 16 oz. Bottle
47
12
10886-125
HFB 5/16-18 x 1.25, Gr. 8
17
2
10502-001
HFB M10-1.5 x 30 CL 10.9
48
2
10947-005
Lower Axle Clamp
18
2
10570-006
UCA (21.080”)
49
2
10949-003
Upper Axle Clamp
19
3
10586-001
Sensor
50
1
10951-004
Track Rod Axle Mount, Detroit
20
3
10587-006
Linkage, 3.938" SS
51
1
10951-005
Track Rod Axle Mount, Meritor
21
2
10591-003
Ball Stud 5/16”-18 x 3/4” L
52
2
10953-004
Lower Control Arm
22
2
10597-047
2nd Vol 50 x 450, LH
53
1
11013-004
Asy, Power Supply, Side Mount
23
1
10614-001
Cap, Filler/Breather
54
2
11102-400
HFB 3/4-10 x 4 Gr 8
24
8
10640-005
Bearing Spacer, 1.24 x .812 x .318
55
2
11102-650
HFB 3/4-10 x 6-1/2 Gr 8
25
1
10680-001
Driver Interface
56
1
11104-002
LH Front Hanger
26
1
10704-009
Wiring Harness, Dash, M2
57
1
11105-002
RH Front Hanger
27
1
10733-004
Steering Linkage Mnt
58
1
11109
28
1
10741-002
Steering Sensor Mnt
59
1
11185-003
Strut, Port Right
29
1
10790-020
Upper Strut Mount, LH
60
1
1118-004
Strut, Port Left
30
1
10790-021
Upper Strut Mount, RH
61
1
11198-001
Track Rod
31
1
10795-008
Mount, Cross member, LH
62
1
11204
48
DESCRIPTION
Kit, Power Module Mounting
Kit, Drawing, Freightliner M2-S
DS150FR-S
DS150FR-SF
49
DS150FR-S
DS150FR-SF
ITEM
QTY
PART NUMBER
DESCRIPTION
ITEM
QTY
PART NUMBER
1
1
10001-005
HCS 3/4-16 x 4-1/2 Gr 8
32
1
10795-011
Mount, Cross member, RH
2
2
10002-550
HCS 7/8”-9 x 5-1/2” Gr 8
33
1
10796-007
Cross member Channel
3
2
10003-003
HCS 1”-8 x 6”, Gr. 8
34
1
10811-011
Mount Template, Detroit Axle
4
2
10003-004
HCS 1”-8 x 6-1/2” Gr. 8
35
1
10811-012
Mount Template, Meritor Axle
5
2
10006-003
HFW 7/8”
36
1
10811-014
Frame Drilling Template
6
4
10006-004
HFW 1”
37
1
10815-001
Wiring Harness, Fused Battery
Lead
7
4
10012-003
LFN 1”-8, Gr G Top Lock
38
2
10830-019
Volume Mount, Double Tank
8
12
10012-007
LFN 1/2”-13, Gr. G
39
4
10843-003
T-Bolt Clamp, Range 4.88-5.5
9
28
10012-008
LFN 5/8”-11 Gr G
40
5
10855-002
Vinyl-Coated Loop Clamp, 1” ID
10
18
10012-010
LFN 5/16”-18, Gr. G
41
7
10855-003
Vinyl-Coated Loop Clamp, 5/8" ID
11
9
10012-012
LFN 3/4”-16, Gr. G
42
2
10867-003
Jounce Bumper, 2.375"Dia x 3.00"T
12
4
10012-014
LFN 3/4”-10 Gr G
43
24
10874-200
HFB 5/8-11x2.000, Gr. 8
13
2
10012-017
LFN 7/8”-9, Gr G
44
2
10874-375
HFB 5/8-11x3.750, Gr. 8
14
4
10064-005
U-Bolt 3/4-16 x 9.03 Tri-8
45
2
10874-600
HFB 5/8-11 x 6", Gr. 8
15
1
10474-001
Silicone Oil, 16 oz. Bottle
46
12
10885-150
HFB 1/2-13x1.500, Gr. 8
16
2
10502-001
HFB M10-1.5 x 30 CL 10.9
47
16
10886-125
HFB 5/16-18 x 1.25, Gr. 8
17
2
10570-006
UCA (21.080”)
48
2
10947-005
Lower Axle Clamp
18
3
10586-001
Sensor
49
2
10949-003
Upper Axle Clamp
19
3
10587-006
Linkage, 3.938" SS
50
1
10951-004
Track Rod Axle Mount, Detroit
20
2
10591-003
Ball Stud 5/16”-18 x 3/4” L
51
1
10951-005
Track Rod Axle Mount, Meritor
21
1
10597-069
2nd Vol 50 x 450, LH
52
2
10953-004
Lower Control Arm
22
1
10597-070
2nd Vol 50 x 450, RH
53
1
11013-004
Asy, Power Supply, Side Mount
23
1
10614-001
Cap, Filler/Breather
54
2
11102-400
HFB 3/4-10 x 4 Gr 8
24
8
10640-005
Bearing Spacer, 1.24 x .812 x .318
55
2
11102-650
HFB 3/4-10 x 6-1/2 Gr 8
25
1
10680-001
Driver Interface
56
1
11104-002
LH Front Hanger
26
1
10704-009
Wiring Harness, Dash, M2
57
1
11105-002
RH Front Hanger
27
1
10733-004
Steering Linkage Mnt
58
1
11109
28
1
10741-002
Steering Sensor Mnt
59
1
11185-003
Strut, Port Right
29
1
10790-020
Upper Strut Mount, LH
60
1
1118-004
Strut, Port Left
30
1
10790-021
Upper Strut Mount, RH
61
1
11198-001
Track Rod
31
1
10795-008
Mount, Cross member, LH
62
1
11204
50
DESCRIPTION
Kit, Power Module Mounting
Kit, Drawing, Freightliner M2-S
DS150FR-S
DS150FR-SS
51
DS150FR-S
DS150FR-SS
ITEM
QTY
PART NUMBER
DESCRIPTION
ITEM
QTY
PART NUMBER
1
1
10001-005
HCS 3/4-16 x 4-1/2 Gr 8
33
1
10795-008
Mount, Cross member, LH
2
2
10002-550
HCS 7/8”-9 x 5-1/2” Gr 8
34
1
10795-011
Mount, Cross member, RH
3
2
10003-003
HCS 1”-8 x 6”, Gr. 8
35
1
10796-007
Cross member Channel
4
2
10003-004
HCS 1”-8 x 6-1/2” Gr. 8
36
1
10811-011
Mount Template, Detroit Axle
5
2
10006-003
HFW 7/8”
37
1
10811-012
Mount Template, Meritor Axle
6
4
10006-004
HFW 1”
38
1
10811-014
Frame Drilling Template
7
4
10012-003
LFN 1”-8, Gr G Top Lock
39
1
10815-001
Wiring Harness, Fused Battery
Lead
8
8
10012-005
LFN 3/8-16, Gr G, Z
40
4
10830-015
Volume Mount, Double Tank
9
8
10012-007
LFN 1/2”-13, Gr. G
41
4
10843-003
T-Bolt Clamp, Range 4.88-5.5
10
28
10012-008
LFN 5/8”-11 Gr G
42
4
10855-002
Vinyl-Coated Loop Clamp, 1” ID
11
20
10012-010
LFN 5/16”-18, Gr. G
43
6
10855-003
Vinyl-Coated Loop Clamp, 5/8" ID
12
9
10012-012
LFN 3/4”-16, Gr. G
44
2
10867-003
Jounce Bumper, 2.375"Dia x 3.00"T
13
4
10012-014
LFN 3/4”-10 Gr G
45
24
10874-200
HFB 5/8-11x2.000, Gr. 8
14
2
10012-017
LFN 7/8”-9, Gr G
46
2
10874-375
HFB 5/8-11x3.750, Gr. 8
15
4
10064-005
U-Bolt 3/4-16 x 9.03 Tri-8
47
2
10874-600
HFB 5/8-11 x 6", Gr. 8
16
1
10474-001
Silicone Oil, 16 oz. Bottle
48
8
10885-150
HFB 1/2-13x1.500, Gr. 8
17
8
10501-002
HFB 3/8-16 x 1.250, Gr 8, BO
49
18
10886-125
HFB 5/16-18 x 1.25, Gr. 8
18
2
10502-001
HFB M10-1.5 x 30 CL 10.9
50
2
10947-005
Lower Axle Clamp
19
2
10570-006
UCA (21.080”)
51
2
10949-003
Upper Axle Clamp
20
3
10586-001
Sensor
52
1
10951-004
Track Rod Axle Mount, Detroit
21
3
10587-006
Linkage, 3.938" SS
53
1
10951-005
Track Rod Axle Mount, Meritor
22
2
10591-003
Ball Stud 5/16”-18 x 3/4” L
54
2
10953-005
Lower Control Arm
23
1
10597-071
2nd Vol 50 x 450, LH
55
1
11013-004
Asy, Power Supply, Side Mount
24
1
10597-072
2nd Vol 50 x 450, RH
56
2
11102-400
HFB 3/4-10 x 4 Gr 8
25
1
10614-001
Cap, Filler/Breather
57
2
11102-650
HFB 3/4-10 x 6-1/2 Gr 8
26
8
10640-005
Bearing Spacer, 1.24 x .812 x .318
58
1
11104-002
LH Front Hanger
27
1
10680-001
Driver Interface
59
1
11105-002
RH Front Hanger
28
1
10704-009
Wiring Harness, Dash, M2
60
1
11109
29
1
10733-004
Steering Linkage Mnt
61
1
11185-003
Strut, Port Right
30
1
10741-002
Steering Sensor Mnt
62
1
11185-004
Strut, Port Left
31
1
10790-020
Upper Strut Mount, LH
63
1
11198-001
Track Rod
32
1
10790-021
Upper Strut Mount, RH
64
1
11204
52
DESCRIPTION
Kit, Power Module Mounting
Kit, Drawing, Freightliner M2-S
DS150FR-S
Electrical Schematics
53
DS150FR-S
54
DS150FR-S
55
DS150FR-S
Appendix A: Drill Locations
Figure 51. Driver Side Upper Strut Mount Frame Drilling.
Figure 52. Passenger Side Upper Strut Mount Frame Drilling.
56
DS150FR-S
Figure 53. Volume Mount Drill Locations, DS150FR-S Only.
Figure 54. Volume Mount Drilling Location, DS150FR-SF Passenger Side.
Figure 55. Volume Mount Drilling Location, DS150FR-SS Passenger and Driver Side.
57
DS150FR-S
Appendix B: Electrical Terminals
Signal
OEM Connector
Body Builder
Reference Guide
Page
Pin
Terminal P/N
Power
Power Net Distribution Box (PNDB)
6
D
or
4
Ignition
Transmission Interface Connector
32
1
Speed
Transmission Interface Connector
32
5
Brake
Body Builder Lighting Interface
23
4
APEX 2.8mm Female
FTL: 23-13211-000 (to -004)
Delphi/FCI: 10810375
APEX 1.5mm Male
FTL: 23-13211-031
Delphi: 54001626 or 13630404
APEX 1.5mm Male
FTL: 23-13211-031
Delphi: 54001626 or 13630404
APEX 2.8mm
Male
FTL: 23-13211-010
Delphi: 54001801RWC
FTL: Freightliner service part number
58
LiquidSpring
Harness
LiquidSpring Wire Color
Dash
Red (in “Vehicle
Connections” bundle)
Dash
Yellow (in “Vehicle
Connections” bundle)
Violet/White
External Harness
Pink/Black
External Harness
DS150FR-S
INSTALLATION CHECK LIST
Installer:
Installation Date:
Inspector:
Inspection Date:
Suspension S/N:
VIN:
FRAME PREPARATION:
☐Battery Disconnected
☐Upper Strut Mount, and Secondary Volume Asy holes drilled.
AXLE PREPARATION:
☐Weld Track Rod Mount to Axle
☐OEM M16 bolts reinstalled and torqued to 140 ft-lbs.
FRONT HANGER INSTALLATION:
☐Front Hangers are level with framerail.
☐5/8”-11 Nuts torqued to 172-210 ft-lbs.
UPPER STRUT MOUNT/UPPER CROSSMEMBER/CROSS MEMBER REINFORCEMENT:
☐Upper Strut Mounts level with top of frame.
☐Upper Cross member orientated correctly.
☐Bolts oriented per Installation Manual Views.
☐5/8”-11 Nuts torqued to 172-210 ft-lbs.
☐1/2”-13 Nuts torqued to 86-105 ft-lbs.
AXLE CLAMP INSTALLATION:
☐3/4”-16 U-Bolts torqued in stages up to 300 ft-lbs.
CONTROL ARMS INSTALLATION:
☐Lower Control Arms correctly orientated.
☐1”-8 Nuts torqued to 600 ft-lbs, at ride height.
☐5/8”-11 Nuts torqued to 172-210 ft-lbs at ride height.
TRACK ROD INSTALLATION:
☐7/8”-14 Nuts torqued in stages up to 491-600 ft-lbs.
STRUT INSTALLATION:
☐Struts ports orientated correctly.
☐3/4”-10 Lower Nuts torqued to 275-300 ft-lbs.
JOUNCE BUMPER INSTALLATION:
☐M10-1.5 Bolts torqued to 35 ft-lbs.
HEIGHT SENSOR INSTALLATION:
☐5/16”-18 Nuts torqued to 14-17 ft-lbs.
☐Linkage Locks installed.
POWER MODULE/SECONDARY VOLUME INSTALLATION:
☐1/2”-13 Nuts torqued to 86-105 ft-lbs.
☐3/8”-16 Screws torqued to 39 ft-lbs.
☐Reservoir Mount Self Tapping Screws tightened to snug only.
☐5/16”-24 T-Clamp Fasteners torqued to 240 in-lbs.
☐Replaced Top Plug with Breather Cap.
59
DS150FR-S
HOSE INSTALLATION:
☐-4 Hose Fittings torqued to 12 ft-lbs.
☐-10 Hose Fittings torqued to 36-63 ft-lbs.
☐Bleed Screws closed and torqued to 13-18 ft-lbs.
☐Hoses secured with loop clamps.
☐5/16”-18 Nuts torqued to 14-17 ft-lbs.
STEERING SENSOR INSTALLATION:
☐3/4”-16 Nut torqued to 215-245 ft-lbs.
☐OEM Nut torqued to 90 ft-lbs.
☐5/16”-18 screws tightened to 14-17 in-lbs.
☐Linkage Locks installed.
WIRING HARNESS INSTALLATION:
☐Dash harness installed
☐All appropriate wiring splices made.
☐Driver Interface installed and connected to Dash Harness.
☐External harness routed and secured.
☐External harness connected to Rate Valves, Height Sensors.
☐Brake signal from external harness inserted into pin 4 of the Body Builder Lighting Interface.
☐Speed signal from external harness inserted into pin 5 of Transmission Interface Connector.
☐Ignition signal from dash harness inserted into pin 1 of Transmission Interface Connector.
☐Power from dash harness inserted into pin 4 of the Power Net Distribution Box ATC Fuse Output Connector.
☐Battery harness installed with Fuse Lead and connected to Battery and Power Module.
☐Door harness installed (if equipped with rear door switch).
☐All connections sealed.
☐All harnesses properly secured from chaffing, heat, and located away from moving parts..
INTIAL FILL/CALIBRATION:
☐Battery connected.
☐Suspension rose to ride height.
☐Reservoir at proper level.
☐Calibration completed.
60
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