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D11342 Rev A
9/30/2016
Contents
CONTENTS ........................................................................... 2
INTRODUCTION ................................................................. 3
ABBREVIATIONS ................................................................ 4
HYDRAULIC FITTING ASSEMBLY ................................ 4
SAE O-Ring Adjustable Fittings ................................ 4
SAE O-Ring Non-Adjustable Fitting .......................... 4
JIC 37° Fitting ........................................................... 5
PRE-INSTALLATION.......................................................... 5
CHASSIS PREPARATION .................................................. 5
FRAME DRILLING .............................................................. 6
BRAKE LINES ...................................................................... 7
PART IDENTIFICATION: .................................................. 8
BOM: DS129FS3, DS147FS3/DS147FS3B .............. 9
INSTALLATION ................................................................. 10
Front Hangers ......................................................... 10
Upper Strut Mounts ................................................. 11
Bridge and Axle Clamp Hangers ............................. 12
Control Arms ........................................................... 13
Track Rod and Tie Bar ............................................ 14
Strut Assembly Installation ...................................... 15
Height Sensors ......................................................... 16
Steering Sensor Installation ..................................... 17
Power Module Installation. ..................................... 18
Secondary Volumes.................................................. 19
Brake Cables ........................................................... 20
Hydraulic Hose Attachment and Routing ................ 21
External Electrical Installation: .............................. 22
Dash Harness Installation ....................................... 23
Driver Interface Installation: .................................. 24
Optional Door Electrical Harness Installation: ...... 24
Initial System Fill..................................................... 24
Bleeding the System ................................................. 25
Calibrating the System ............................................. 25
SYSTEM OPERATION ...................................................... 26
System Start Up: ...................................................... 26
ON/OFF Button: ...................................................... 26
Warning Light: ........................................................ 26
Ride Mode Adjustment: ........................................... 26
Ride Height Adjustment: .......................................... 26
Depressurizing the System ....................................... 27
Calibrating the Steering Sensor Only ...................... 28
Calibrating the System (Full) .................................. 28
Checking Fluid Level ............................................... 28
Checking Fittings for Leaks ..................................... 29
SERVICE INTERVALS ..................................................... 29
Once Daily or Before Each Shift of Usage .............. 29
2
Initial 1,000 mile (1,600 km) Inspection.................. 29
TROUBLESHOOTING ...................................................... 30
Issues with Vehicle Raising/Pump ........................... 30
Issues with Vehicle Lowering/Dump Valve ............. 30
Issues with One Corner Not Leveling Properly ....... 31
Issues with Height Sensors ...................................... 31
Issues with Ride/Handling ....................................... 31
Issues with Steering Sensor ..................................... 31
Issues with Vehicle Speed Signal ............................. 32
Issues with Vehicle Brake Signal ............................. 32
Issues with Door Switch .......................................... 32
Issues with Vehicle Ignition Signal .......................... 32
Issues with Vehicle Park Signal .............................. 32
Issues with Driver Interface .................................... 32
Issues with Power Module ....................................... 33
Issues with Strut Assembly ...................................... 33
Issues with Secondary Volume Assembly ................ 34
APPENDIX A: ELECTRICAL SCHEMATICS ............. 35
WARRANTY CONDITIONS ............................................. 39
INSTALLATION CHECK LIST ....................................... 41
Introduction
This manual provides installation information for the
LiquidSpring CLASS® DS129FS3, DS147FS3, and
DS147FS3B series of rear axle suspension systems for the
Ford F450/F550 Cab Chassis.
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 proper tools when required to help avoid serious personal injury and damage to components.
Throughout this manual, important product information is indicated. 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.
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 and Rating
Model
F450
F550
Model
Years
2017-
Current
Rear
Axle
1
GAWR
12,880
13,660-
14,706
LiquidSpring
Kit
DS129FS3
DS147FS3
DS147FS3B
LiquidSpring
Suspension
Rating (lbs)
12,880
14,706
Serial Number Tag Information
The serial number is found on an aluminum tag 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.
WARNING:
Overloading suspension system may result in abnormal handling characteristics and premature wear of
components.
Figure 1. Suspension Identification
Figure 2. Serial Number Tag Location
3
Vehicle Towing and Jacking Information
Before attempting any type of towing procedures, contact the
Chassis OEM or Vehicle Manufacturer for instructions.
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.
Do not attach tow apparatus (hooks, chains, straps, etc.) to the suspension components.
Abbreviations
The following abbreviations will be used throughout the manual.
HCS Hex Cap Screw (also HB)
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
Hydraulic Fitting Assembly
SAE O-Ring Adjustable Fittings
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.
Figure 4. Locknut completely backed off.
WARNING: Attaching towing equipment to improper locations and failure to utilize Chassis OEM or Vehicle
Manufacturer recommended towing methods could result in one or more of the following:
Damage to the suspension and/or vehicle,
Loss of vehicle control,
Possible disconnect from the vehicle.
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.
HFW Hardened Flat Washer
SLW Spring Lock Washer
FW Flat Washer
SAE SAE O-Ring Fitting
37°
LH
SAE or JIC 37° Flare Fitting (F – Female)
Left Handed Part
RH Right Handed Part
UCA Upper Control Arm
LCA Lower Control Arm
USM Upper Strut Mount
PM Power Module
4.
Back off lock nut as far as possible. Make sure backup washer is not loose and is pushed up as far as possible.
5.
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.
6.
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.
7.
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.
8.
Inspect to ensure that O-ring is not pinched and that washer is seated flat on face of port.
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.
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.
4
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.
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.
Pre-Installation
1.
Check the vehicle 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 tire-to-frame dimensions on each side prior to disassembly.
Chassis Preparation
1.
Chock the front tires.
2.
Jack up the rear frame of the vehicle to remove the load from the rear leaf springs.
3.
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 after leafs are removed.
4.
Disconnect the negative vehicle battery cable.
5.
Remove the OEM shock absorbers.
Note:
Retain driver side upper shock mount nut, to be reused in
Track Rod / Tie bar installation.
6.
Remove the OEM leaf springs and rear shackles.
Retain front spring hanger hardware where the hanger bolts through the lower flange
Note: It’s not necessary to remove the rear shackle hanger from the frame.
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
-10 fitting:
36-63 ftlbs
-8 fitting:
27-39 ft-lbs
-12 fitting:
65-88 ftlbs
7.
Remove the OEM spring overload pads riveted to the frame.
8.
If equipped with midship fuel tank, dropping the tank may ease installation, but is not necessary.
Note: Do not remove OEM Jounce Bumpers. If they are removed, they will need re-installed prior to Upper strut mount / track rod mount installation.
9.
Disconnect the parking brake cable and remove the driver side parking brake cable bracket mounted just
in front of the front leaf hanger, See Figure 5.
Figure 5: Remove Parking Brake Bracket
10.
Disconnect the axle mounted parking brake cable guide, located on the passenger side shock mount.
This will need relocated to the control arm mount in later steps.
5
Frame Drilling
WARNING: Use caution when drilling, making sure fuel systems, brake lines, and electrical wiring are protected and do not get damaged.
2.
Locate the “knockout” template which is inside the template previously used for marking the upper strut mount holes. It must be broken out of the template
Figure 6. Location of Drill Template on Dr. Side Frame
1.
Center punch, mark holes, and drill as indicated in
Figure 9: Location of Knockout
3.
Insert the template inside the fuel tank crossmember
as shown in Figure 10 and center punch, mark holes, and drill as indicated in Figure 11.
Figure 7: Driver side template location for upper strut mount frame drilling.
Figure 10: Locate template inside crossmember channel as shown behind the exhaust
Figure 11: Mark and drill holes as indicated.
4.
Locate the Volume Mounting Brackets and place along frame as shown in Secondary Volume
Installation for additional drill locations.
Figure 8: Passenger side template location for upper strut mount and track rod frame mount frame drilling.
6
Brake Lines
NOTE: The following procedures should be used in conjunction with OEM Hydraulic Brake service instructions and procedures.
1.
Locate the two hydraulic brake lines, banjo bolts, and copper crush washers included in the kit.
Figure 12: Brake Line Kit P/N: 11326
2.
On the rear axle, locate the OEM LH Rear brake outer flexible hose.
NOTE: Removal of the wheel and tires may aid in the following steps, but not necessary.
6.
Connect the OEM brake line into the tube fitting – torque to 159 in-lbs and install the banjo fitting with the banjo bolt and crush washers to the caliper – torque to 35 ft-lbs.
7.
Follow the same procedure for the RH flexible brake hose.
8.
Locate the OEM axle mounted inner brake hose bracket.
9.
Detach the axle vent hose retainer clip, and the hydraulic brake tube retainer clips.
10.
Disconnect the hydraulic brake tube fittings, and remove the axle vent hose fitting from the axle.
11.
Replace the OEM bracket with the provided bracket which will raise the brake tube fittings higher off the axle.
12.
Install the Vent hose fitting, and brake tube fittings through the bracket - torque to 159 in-lbs.
13.
Install the OEM retainer clips, re-attach the vent hose clip, and re-install the wheel speed sensor harness retainers.
Figure 13: OEM Brake Line Removal
3.
Remove the banjo bolt and disconnect the brake hose from the LH caliper.
4.
Disconnect the brake tube fitting, remove the brake hose bracket bolt from the axle, and remove the hose.
Figure 15: Axle Mounted Brake line standoff
14.
Bleed the brake system. Refer to OEM service instructions (206-00 Brake System – General
Information, General Procedures).
NOTE: Follow OEM specified brake bleeding procedure.
Use DOT 4 Low Viscosity High Performance Motor Vehicle
Brake Fluid, such as Motorcraft PM-20.
NOTE: A pressure bleed system may be used to simplify one-
Figure 14: Replacement DR Side Brake components
5.
Install the new brake hose bracket (10806-010) using the OEM M8 fastener, torque to 159 in-lbs.
Insert the provided hydraulic line fitting through the brake hose bracket and secure using the bowed retainer clip.
Figure 16: An example of pressure bleed system: Mityvac
MV6840
7
Part Identification:
DS129FS3, DS147FS3, and DS147FS3B
8
BOM: DS129FS3, DS147FS3/DS147FS3B
ITEM
1
2
6
7
8
3
4
5
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
QTY
1
2
8
8
13
10
1
8
2
19
18
8
4
13
2
1
1
8
2
1
1
2
4
1
1
2
PART NUMBER
10002-550
10002-850
10003-004
10004-024
10006-003
10006-004
10012-003
10012-005
10012-007
10012-008
10012-010
10012-012
10012-014
10012-017
10064-007
10474-001
10501-150
10586-001
10586-002
10587-002
10587-008
10591-001
10597-087
10597-088
10614-001
10640-005
DS129FS3, and DS147FS3/DS147FS3B
DESCRIPTION
HB .875-9x5.500, Gr. 8
ITEM
39
QTY
1
HB .875-9x8.500, Gr. 8
40
1
HB 1.000-8x6.500, Gr. 8
41
2
LHN 1/4-20, Gr. 2
42
1
HFW .875
43
1
HFW 1.000
44
1
LFN 1-8, Gr G
45
4
LFN 3/8-16, Gr G
46
2
LFN 1/2-13, Gr. G
47
4
LFN 5/8-11 Gr G
48
4
LFN 5/16-18, Gr. G
49
7
LFN 3/4-16, Gr. G
50
1
LFN 3/4-10 Gr G
51
15
LFN 7/8-9, Gr. G
52
4
U-Bolt, 3/4-16 x 8.00 Tri-8
53
10
Silicone Oil, 16 oz. Bottle
54
14
HFB 3/8-16 x 1.500, Gr. 8
55
4
Height Sensor
56
1
Steering Sensor
57
2
Linkage
58
2
Linkage, 3.281" OP 1
59
Ball Stud, 10mm x 5/16-18 1
Volume Assembly, LH
Volume Assembly, RH
60
1
1
Cap, Filler/Breather
Bearing Spacer
61
1
2
26
27
1
1
10669-002
10680-001
U-Bolt, 1/4-20
Driver Interface
62
63
1
1
28
29
30
31
32
1
1
1
1
1
10704-011
10729-014
10730-008
10733-001
10741-001
Dash Harness
Front Hanger, RH
Front Hanger, LH
Steering Linkage Mount
Steering Sensor
64
65
66
67
68
1
1
2
2
2
33
34
35
36
37
38
1
1
2
1
1
10745-012
10762-011
10782-013
10782-014
10789-019
Upper Axle Seat
Bridge
Crossmember Reinf.
OEM Crossmember Reinf.
Track Rod Mnt
69
70
71
72
1
1
1
11185-007
11057-008
11185-008
11102-400
11102-650
11114-005
11115-016
11198-002
11208-002
11222-001
11222-004
11326
11333-001
11339
11341
PART NUMBER
10790-033
10790-034
10806-010
10806-011
10811-022
10815-001
10830-013
10839-003
10843-003
10855-002
10855-003
10855-004
10874-175
10874-200
10885-150
10886-100
10886-125
10902-002
10910-005
10947-011
11057-007
USM, LH
DESCRIPTION
USM, RH
Brake Line Restraint
Brake Line Axle Stand-Off
Drill Template
Fused Battery Lead
Volume Mount
Retaining Ring, Bowed
T-Bolt Clamp
Loop Clamp, 1" ID
Loop Clamp, 5/8" ID
Loop Clamp, 3/8" ID
HFB 5/8-11x1.75, Gr. 8
HFB 5/8-11x2.00, Gr. 8
HFB 1/2-13x1.50, Gr. 8
HFB 5/16-18 x 1.00, Gr. 8
HFB 5/16-18 x 1.25, Gr. 8
Park Brake Cable Mount
Spacer Plate (84CA)
Lower Axle Cradle
LH Strut Asy DS129FS3
LH Strut Asy DS147FS3/B
RH Strut Asy DS129FS3
RH Strut Asy DS147FS3/B
HFB 3/4-10 x 4 Gr 8
HFB 3/4-10 x 6-1/2 Gr 8
Tie Plate Mnt
Tie Plate
Track Rod
Asy, Power Supply
Lower Control Arm
Upper Control Arm
Hyd. Brake Hose, 90 Banjo
Reflective Thermasheild
Pwr Mod Mnt Kit
Document Kit
9
Installation
Front Hangers
ITEM
1
2
3
4
QTY.
8
1
1
8
PART NUMBER
10012-008
10729-014
10730-008
10874-175
DESCRIPTION
LFN 5/8-11 Gr. G
RH Front Hanger
LH Front Hanger
HFB 5/8-11 x 1.75” Gr. 8
1.
Install the hangers as shown with supplied and OEM fasteners through OEM front hanger holes.
Note: Snug OEM fasteners on frame flange prior to tightening 5/8” fasteners to ensure hanger is flush with bottom of frame rail.
2.
Torque Fasteners to
172-210 ft-lbs.
10
Upper Strut Mounts
ITEM
1
2
3
4
5
6
QTY
5
7
10
5
1
1
PART NUMBER
10012-005
10012-007
10012-008
10501-150
10782-013
10782-014
DESCRIPTION
LFN 3/8-16, Gr. G
LFN 1/2-13 Gr. G
LFN 5/8-11 Gr. G
HFB 3/8-16x1-1/2”, Gr. 8
Cross-member Reinforcement
OEM Crossmember Reinf.
1.
Loosely attach all components through previously drilled holes in the frame and crossmember.
ITEM
7
8
9
10
11
12
QTY
1
1
1
6
4
7
PART NUMBER
10789-019
10790-033
10790-034
10874-175
10874-200
10885-150
DESCRIPTION
Track Rod Mount
USM, LH
USM, RH
HFB 5/8-11x1.75, Gr. 8
HFB 5/8-11x2”, Gr. 8
HFB 1/2-13x1-1/2”, Gr. 8
Section A-A, Detail of Cross-member Orientation
Figure 17: OEM Crossmember Reinforcement installed
IMPORTANT: Bolts must be installed in directions as shown to provide clearance to the Struts and other Moving parts. No bolts should be pointed towards the fuel tank.
IMPORTANT: Before tightening fasteners, verify the top of each upper strut mount is level with the top of the frame. Placing a jack under the USM helps to ensure mounts are flush to the bottom frame flange.
11
2.
Torque all fasteners as shown above.
Bridge and Axle Clamp Hangers
ITEM
1
2
3
QTY
8
4
2
PART NUMBER
10012-012
10064-007
10745-012
DESCRIPTION
LFN ¾-16 , Gr. G
U-Bolt ¾-16 x 8.0 Tri-8
Upper Axle Seat
1.
Install the Bridge and axle clamp components onto the axle. Note: The LH side of the bridge has a socket head bolt acting as a pin, which locates to the
LH spring seat hole.
2.
Relocate the RH parking brake cable guide to the RH
Lower axle clamp. The cable guide may be tight around the cable and need loosened to enable sliding
the cable inside. See Figure 18, Figure 19, and the
section Parking Brake Cables.
ITEM
4
5
QTY
1
2
PART NUMBER
10762-011
10947-011
Bridge
DESCRIPTION
Lower Axle Cradle
Figure 18: Loosen Cable Guide for Repositioning
12
Figure 19: Relocate OEM Brake line to Axle Clamp
3.
Once you verify the Axle seat is sitting flush to the
Bridge and the Bridge is sitting flush to the axle,
Torque the U-Bolts as indicated above.
Control Arms
ITEM
1
2
3
QTY
8
8
8
PART NUMBER
10003-004
10006-004
10012-003
DESCRIPTION
HB 1-8 x 6-1/2”, Gr. 8
HFW 1”
LFN 1-8, Gr. G
1.
Locate control arms and install as shown.
Note: Height sensor tab is pointed up and located forward on
Lower Control Arms.
2.
Do Not Torque fasteners at this time
. Torque after track rod is installed and axle is held at ride height.
ITEM
4
5
QTY
2
2
PART NUMBER
11222-001
11222-004
DESCRIPTION
Lower Control Arm (LCA)
Upper Control Arm (UCA)
IMPORTANT: Axle must be held at ride height for tightening control arm bolts to prevent premature wear of bushings from excess twist in the rubber.
13
Track Rod and Tie Bar
ITEM
1
2
3
4
5
6
QTY
1
1
2
1
1
2
PART NUMBER
10002-550
10002-850
10006-003
10012-007
10012-008
10012-017
DESCRIPTION
HCS 7/8-9 x 5.5” Gr 8
HCS 7/8-9 x 8.5” Gr 8
HFW 7/8”
LFN 1/2-13, Gr. G
LFN 5/8-11 Gr G
LFN 7/8-9 Gr G
Note: Prior to installing Tie Bar Mount, one hole will need drilled in the frame.
Caution: When drilling through the frame rail, use caution not to drill into fuel, electrical, or brake lines.
1.
Using the tie plate mount as a template, install the tie plate onto the LH shock mount, hold level to the frame, and mark the frame for drilling a Ø17/32” hole to allow mounting with 1/2” hardware. See
ITEM
7
8
9
10
11
QTY
1
1
1
1
1
PART NUMBER
10874-175
10885-150
11114-005
11115-006
11198-002
DESCRIPTION
HFB 5/8-11 x 1.75, Gr. 8
HFB 1/2-13 x 1.50, Gr. 8
Tie Plate Mount
Tie Plate
Track Rod
2.
Install components as shown above.
3.
Jack each side of the axle until approximately design
ride height position. See Figure 21.
4.
Torque the two (2) 7/8” Track Rod mounting bolts to
491-600 ft-lbs.
5.
Torque the eight (8) 1” Control Arm mounting bolts to
600 ft-lbs.
Figure 20: Tie plate mount installed on LH shock mount, for locating hole to drill.
14
Figure 21: Adjust frame or axle to ride height when tightening control arm and track rod fasteners.
IMPORTANT: Vehicle must be at ride height when tightening control arms and track rod, to prevent premature wear of bushings from excess twist in the rubber.
Strut Assembly Installation
ITEM
1
2
3
QTY
4
8
1
PART NUMBER
10012-014
10640-005
11057-007
11185-007
DESCRIPTION
LFN 3/4-10 Gr G
Bearing Spacer
LH Strut DS129FS3
LH Strut DS147FS3/147FS3B
ITEM
4
5
6
1.
Install the Left Hand Strut Assembly as shown with strut hydraulic ports forward.
2.
Repeat for installation of Right Hand Strut Assembly,
Bearing Spacers, and Hardware.
QTY
1
2
2
PART NUMBER
11057-008
11185-008
11102-400
11102-650
DESCRIPTION
RH Strut DS129FS3
RH Strut DS147FS3/147FS3B
HFB 3/4-10 x 4” Gr 8
HFB 3/4-10 x 6-1/2” Gr 8
3.
Torque upper and lower strut fasteners to
275-300 ftlbs
.
Do not over torque.
15
Height Sensors
ITEM
1
2
3
QTY
6
2
2
PART NUMBER
10012-010
10586-001
10587-008
DESCRIPTION
LFN 5/16-18, Gr. G
Height Sensor Assembly
Linkage Assembly
IMPORTANT: Strut assemblies must be installed prior to the installation of the height sensors to prevent over-travel of sensors which could damage sensor components.
1.
Install Height Sensor components and hardware as shown.
2.
Torque all 5/16 hardware to
14-17 ft-lbs.
3.
Snap the Linkage Assemblies to the ball studs attached to the lower control arms and to the ball studs on the Height Sensor arms.
Install rod end
ITEM
4
5
QTY
2
4
PART NUMBER
10591-001
10886-125
DESCRIPTION
Ball Stud 5/16-18
HFB 5/16-18 x 1.25, Gr. 8
Figure 22, Height Sensor Linkage Installation.
16
Steering Sensor Installation
ITEM
1
2
3
4
QTY
1
1
1
1
PART NUMBER
10587-002
10733-001
10741-001
10586-002
DESCRIPTION
Asy, Linkage
Steering Linkage Mount
Steering Sensor Mount
Steering Sensor
1.
Raise the front end of the vehicle, per OEM instructions.
2.
Remove and retain upper two of three nuts securing
front track rod mount to cross member. See Figure
ITEM
5
6
7
QTY
1
2
2
PART NUMBER
10669-002
10004-024
10886-100
DESCRIPTION
U-Bolt, 1/4-20
LHN 1/4-20, Gr. 2
HFB 5/16-18 x 1.00, Gr. 8
6.
7.
Install steering linkage mount to the pitman arm, ensuring it is pressed up against the flange/boss on pitman arm.
Attach linkage to ball studs and install locks.
Note: In some instances the linkage lock on the pitman arm side may need to be left off due to tight clearance.
Important: Verify the steering sensor components do not bind or interfere during full travel of the steering
Figure 23. Track rod mount bolts to temporarily remove
3.
Install bracket over two bolts and reinstall OEM nuts.
Torque to
120 – 147 ft-lbs
4.
Route the steering sensor branch containing the J35 steering sensor connector.to the steering sensor.
Important: Verify the wiring harness does not contact heat source or moving components.
5.
Connect the electrical connector to the steering sensor prior to installation of the Steering Sensor.
17
Power Module Installation.
ITEM
1
2
3
4
5
QTY
1
1
1
3
2
PART NUMBER
10799-022
10798-026
10510-006
10252-004
10252-003
DESCRIPTION
Manifold Mount
Reservoir Mount
STS 3/6-16 x 1.50” Hex Head
SFHS 3/8-16 x 1-1/4” Gr 8.2
SFHS 3/8-16 x 5/8” Gr 8.2
1.
Locate the Power Module Assembly and Power
Module Mounting Kit.
2.
Assemble as instructed in the kit, and mount onto chassis under the cab on the driver side.
ITEM
6
7
8
9
10
QTY
2
2
2
2
3
PART NUMBER
10322-021
10805-004
10088-001
10510-002
11327-001
DESCRIPTION
Hyd. Fit. 90, -4 37 x -4 37 F
Grommet
FW #10
STS #10-16 x 3/4” Hex Head
UN 3/8-16, ¾ Hole to Edge
18
Figure 24: Power module location on truck
Secondary Volumes
ITEM
1
2
3
4
5
6
QTY
8
6
8
1
1
1
PART NUMBER
10012-005
10012-010
10501-150
10597-087
10597-088
10614-001
DESCRIPTION
LFN 3/8-16 Gr G
LFN 5/8-18 Gr G
HFB 3/8-16 x 1-1/2” Gr 8
Volume Asy, LH
Volume Asy, RH
Breather/Fill Cap
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.
1.
Locate and Place the mounts against the driver side
frame, forward of the front hanger. See Figure 25
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. See Figure 25 for dimensions.
2.
Verifying the mounts are held flush to the bottom of the frame and utilizing the mount hole pattern, mark the locations of the mounting holes and drill (2)
Ø7/16” holes per mount.
3.
Attach the two mounts with 3/8” Flange Bolts and
Nuts. Torque to
35-43 ft-lbs
. Note: Orientate nuts outboard.
4.
Repeat with Volume Mounts on the passenger side of the frame.
5.
Raise the volume assembly until the volume contacts both mounts. Rotate the volume assembly until the
ITEM
7
8
9
10
11
12
QTY
4
4
4
5
4
2
PART NUMBER
10830-013
10843-003
10855-002
10855-003
10886-100
10910-005
DESCRIPTION
Volume Mounts
T-Bolt Clamp
Vinyl Coated Loop Clamp 1”
Vinyl Coated Loop Clamp 5/8”
HFB 5/16-18 x 1” Gr 8
Volume Mount Spacer Plate bleed screws are located to the top and as vertical as possible.
6.
Locate (2) T-Bolt Clamps, open the clamps, and place them in the mounts around the two pegs.
Torque the T-Bolt nut to
240 in-lbs
.
7.
Repeat with opposite side. Note, the 90° Elbows connected to the volume may have to be loosened and re-orientated as necessary.
Figure 25: Suggested Tank Mount Locations
19
Brake Cables
ITEM
1
2
3
QTY
2
2
2
PART NUMBER
10012-005
10012-010
10885-150
DESCRIPTION
LFN 1/2-13, Gr. G
LFN 5/16-18, Gr. G
HFB 1/2-13 x 1.5, Gr 8
1.
Locate and install Parking Brake Cable Mount using
1/2” hardware, and torque to 86-105 ft-lbs, Dry.
2.
Attach Drive Side Cable to the Cable mount.
3.
Attach both OEM Cable Guides to the Cable Mount using 5/16” hardware, and torque to 14-17 ft-lbs,
Dry.
ITEM
4
5
QTY
2
1
PART NUMBER
10886-100
10902-002
DESCRIPTION
HFB 5/16-18 x 1” Gr 8
Parking Brake Cable Mount
Figure 27: Attachment points for Passenger Parking brake cable.
5.
Secure the Passenger hydraulic brake line behind the
axle with a 3/8” loop clamp. See Figure 28
Figure 26: Parking Brakes Installed
4.
Using 5/8” loop clamps and 5/16” hardware, secure the passenger parking brake cable to the Bridge
mounting points as shown in Figure 27
20
Figure 28: Passenger hydraulic brake hose.
Hydraulic Hose Attachment and Routing
ITEM
1
2
QTY
6
4
PART NUMBER
10012-010
10855-002
DESCRIPTION
LFN 5/16”-18 Gr G
Vinyl Coated Loop Clamp, 1”ID
CAUTION: Attachment of the hydraulic hoses may result in some spillage of fluid. Use of oil absorbent mats is recommended.
CAUTION: Make sure hoses are not chafing or in contact with any sharp edges.
1.
Locate -10 hose on Left Hand (driver side)
Secondary Volume and route the hose to strut area, over front hanger and axle.
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 the bleed screw on the -10 hose side of the Left Hand Secondary Volume
Assembly and place the other end in a bucket.
ITEM
3
4
QTY
5
6
PART NUMBER
10855-003
10886-100
DESCRIPTION
Vinyl Coated Loop Clamp, 5/8” ID
HFB 5/16-18 x 1” Grade 8
8.
Secure hose with clamp to front hanger and frame or
Upper strut mount.
9.
Repeat with the opposite side. Note, the -10 90°
Elbow connected to the volume may have to be loosened and re-orientated as necessary.
10.
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.
11.
Open the bleed screw slightly to relieve any residual pressure and after pressure is relieved, close the bleed screw and torque to
13-18 ft-lbs.
12.
Route the Left Hand (Driver side) -4 (1/4”) hydraulic hose to the Power Module. Use hose clamps to secure the hose from movement or chafing.
Figure 29. Bleed screw locations.
4.
Open the bleed screw slightly to relieve any residual pressure.
5.
After pressure is relieved, close the bleed screw and torque to
13-18 ft-lbs.
6.
Remove the cap from the strut port, and Remove the plug from the end of the hose.
7.
Attach the hose end (-10 JIC fitting) to the strut port and torque to
36-63 ft-lbs.
21
Figure 30. -4 Hose Connections, Frame Hidden.
13.
Attach the hose end to the fitting in the port marked
“L”. Torque to
12 ft-lbs. Do not over tighten.
14.
Repeat with the Pass side for the port marked “R”.
15.
Clean up any fluid spillage
External Electrical Installation:
1.
Locate the External Electrical Harness attached to the power module.
2.
Unroll the wiring harness and using the External
Electrical Harness wiring diagram, found in the electrical schematics section, and identify the connection ends.
3.
Locate the trunk containing Height Sensor (J21 and
J22) and the Rate Valve (J23 and J24) connections.
4.
Route and make the following connections to the
Height Sensors.
J21
J22
Left Height Sensor
Right Height Sensor
5.
Route and make the following connections to the
Rate Valves.
J23
J24
Left Rate Valve
Right Rate Valve
6.
Secure harness to OEM harness. Use of plastic clips is recommended.
7.
Install Reflective Thermashield around wiring crossing over the exhaust piping. Supplied is a 4’ section which needs cut in half and installed on
branches J22 and J24. See Figure 31 and Figure 32.
Figure 31: Install 2' sections on each J22 and J24
8.
Locate the 8ga wire ground ring terminal, J30, branch near the power module.
9.
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.
10.
Attach the ground ring terminal, J30, to the chassis frame for grounding. Sealant may be applied after ring terminal is secured.
11.
Route the remaining trunk (containing blunt wires and steering sensor connector) towards the firewall.
Secure to OEM wiring harness.
12.
Locate the existing firewall access hole under the dash, behind the parking brake pedal.
13.
Route the wiring harness branch containing the (8)
18ga blunt wires through the firewall access hole.
Figure 33: 2016 pictured, 2017 similar
14.
Locate the 8ga battery connection branch.
15.
Route branch to the battery positive terminal.
16.
Locate the Battery Fuse Lead containing the 80 amp fuse.
17.
Crimp the fuse lead to the 8ga battery connection branch blunt end.
18.
Melt the heat shrink on the crimped connection to seal the splice.
19.
Remove the 80 amp fuse and retain.
20.
Connect to the positive terminal post per OEM
Upfitter wiring instructions.
Figure 32: Wiring routed through hanger.
22
Dash Harness Installation
1.
Locate the dash harness.
2.
Locate and identify the following 18ga wires in the two external wiring harness branches passed through the firewall:
Red (Battery Power)
Yellow (Ignition)
Black (Ground)
White (CAN High)
White/Black (CAN Low)
Yellow/Black (Park)
Violet/White (Speed)
Pink/Black (Brake)
3.
Crimp each wire to the corresponding blunt wire in the dash harness labeled “External Harness
Connections”. Match wire colors, crimp using butt splices, and install heat shrink.
4.
Locate the four (4) Yellow, Yellow/Black,
Violet/White, and Pink/Black 18ga wires in the dash harness. Route the wires to the Customer Access
Harness located inside the passenger kick panel.
Figure 35: Additional Customer Access Wires – Below the
Underhood Fuse Panel
7.
Make the following connection with the Underhood
Customer Access – Upfitter Harness: Crimp the wire using sealed butt splices. Heat shrink sealing is recommended.
Liquidspring Dash Harness
Red 12ga (Battery)
Ford Customer Access
Brown/Red – 20A B+
8.
Attach the Ground ring terminal (J32) from the dash harness to a ground location under the steering wheel, near the OBD port.
9.
Refit any sheathing and apply appropriate electrical tape and zip ties to secure excess wire.
10.
Replace passenger side plastic kick panel.
Figure 34: Customer Access Harness
5.
Make the following connections with the Customer
Access Harness: Crimp each wire using butt splices.
Heat shrink sealing is recommended.
Liquidspring Dash Harness
Yellow 18ga (Ignition)
Ford Customer Access
Green/Orange – CBP22
Yellow/Black 18ga (Park)
Gray/Brown – TRO-P
Violet/White 18ga (Speed)
Violet/Orange – VS OUT
Pink/Black 18ga (Brake)
Violet – CBP04
6.
Locate the 48” Red 12ga wire in the dash harness.
Route the wire through the firewall grommet to the additional customer access wires located under the fuse panel behind the Driver side battery.
23
Driver Interface Installation:
1.
Locate the Driver Interface.
2.
Mount the Driver Interface to the dash in an appropriate location.
3.
Route the Driver Interface harness to the dash harness connector, J26, and connect.
4.
Secure all wires under the dash.
5.
Replace the 80 amp fuse at the battery.
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 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.
B: Dual Wire – Ground Signal From System
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.
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)
24 accordingly and apply heat to the insulator to seal the connection(s).
Initial System Fill
1.
Install the wheels and tires. Torque wheel nuts to
OEM specifications.
2.
Reconnect the negative cable to the vehicle battery.
3.
Verify that the front wheels are steered straight ahead.
4.
Lower the vehicle to the ground and remove any jack stands from under the vehicle. The suspension should be in the kneeled position.
5.
Locate the container of Compressible Fluid.
6.
Remove the breather cap from the Power Module reservoir.
7.
Fill the reservoir approximately 2/3 full.
8.
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.
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.
9.
Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should go out.
10.
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.
11.
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.
12.
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.
13.
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.
c.
Completely depressurize the system. See
Depressurizing the System section, under System
Operation
14.
After the suspension system stops leveling, check the fluid level in the reservoir. If low, fill to the indicated line.
Figure 36. Final fill fluid level.
Bleeding the System
1.
Locate 3/16” ID PVC Tubing (not included with kit).
Note: Alternatively, a bleed kit similar to the Actron
7840 Bleed Kit or Lisle 19200 Brake Bleeding Kit
(found at Sears) can be used.
2.
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 37. Bleed screw locations.
3.
Open the bleed screw slightly.
4.
After air bubbles are no longer present, close the bleed screw and torque to
13-18 ft-lbs.
5.
Repeat with remaining three bleed screws.
Calibrating the System
IMPORTANT: Proper calibration of the system must be conducted with the vehicle loaded to the as delivered 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.
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.
25
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 “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.
4.
Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should go out.
5.
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.
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.
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.
10.
Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should go out.
11.
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.
12.
Calibration is now completed.
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.
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.
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.
IMPORTANT: After turning the vehicle ignition off, the suspension system will remain powered for 2-1/2 minutes before shutting off.
Warning Light:
If the Red LED warning light is continuously illuminated along with one or more of the other indicator lights,
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.
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.
Ride Height Adjustment:
Press the UP/DOWN arrow buttons to change ride height from NORMAL to HIGH (body up) or LOW (body down).
A solid green LED will indicate the selected height. A flashing green LED will indicate the current height and that height adjustment is
26
occurring. When a single solid green LED is lit, the selected height has been achieved.
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 1 hour 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 1 hour 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.
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.
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.
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:
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 38. Bleed screw locations.
10.
Open the bleed screw slightly to relieve any residual pressure.
27
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 recentered. 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.
Calibrating the System (Full)
See Section
Checking Fluid Level
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.
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.
2.
Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should go out.
3.
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.
4.
After the suspension system stops leveling, check the fluid level in the reservoir. If low, fill to the indicated line.
8.
Figure 39. Final fill fluid level.
Locate a container of Compressible Fluid.
7.
Add fluid to the reservoir until the fluid level is
within the band shown in Figure 39.
Replace filler/breather cap and retighten.
5.
To add fluid, remove filler/breather cap on reservoir.
6.
28
Checking Fittings for Leaks
WARNING: The system operates under high fluid pressure (up to 3500 psi). Do not attempt to locate leaks by feeling with hands or any part of the body.
High pressure fluids can penetrate the skin and cause severe tissue damage.
1.
While system is at ride height and pressurized, visually examine fittings and hose connections for any source of leaks. Do not use hands to search for leak. If the source of the leak is a fitting or other component, depressurize the system and repair or replace as needed.
2.
Tighten hose nuts if the leak is coming from the connection between the hose nut and a fitting.
Depressurize the system before tightening anything.
Replace hose if the leak is coming from anywhere else on the hose.
WARNING: Never tighten a hydraulic fitting or hose under pressure. Always depressurize the system before adjusting fittings and hoses.
3.
Clean all fluid from hose and fittings to visually identify any leaks.
IMPORTANT: Over-tightening hoses and fittings can damage components and lead to leaks.
Service Intervals
Once Daily or Before Each Shift of Usage
Check the suspension system to be sure it is fully operational. o
After starting vehicle, verify all LED’s on the driver display flash briefly, then the
Green Ride Height and Ride Mode LED’s are lit and the Red Warning LED does not stay on or flash. o Verify the four Yellow LED’s are lit when the steering wheel is centered. o
Verify that they system is at NORMAL ride height, with a steady green LED.
If the Driver Display indicates a blinking ride height LED, allow the system to complete leveling as indicated by a steady green LED.
If LOW or HIGH height is shown with a solid green LED, use the arrow buttons to raise or lower the suspension to NORMAL height.
Visually inspect struts, hoses, and fittings for signs of leakage. o
For leakage resulting in fluid pooled on the floor greater than 1” in diameter, it is recommended to service the system immediately. o
For signs of leakage or weeping that results in wetness on components or a single drop, it is recommended to monitor the leak and schedule repair service accordingly.
Initial 1,000 mile (1,600 km) Inspection
Inspect bolts and nuts at the control arm pivots to assure they are properly torqued.
Inspect u-bolts to assure they are properly torqued.
Thoroughly inspect all hydraulic connections for signs of leakage.
Inspect reservoir fluid level.
Routine Maintenance 25,000 miles (40,000 km) or 6 month maximum Interval
Check all suspension components for any signs of damaged/broken components, looseness, or wear.
Inspect bolts and nuts at the control arm pivots to assure they are properly torqued.
Inspect bolts and nuts at both the frame and axle mount ends of the track rod to assure they are properly torqued.
Inspect u-bolts to assure they are properly torqued.
Thoroughly inspect all hydraulic connections for signs of leakage.
Inspect reservoir fluid level.
29
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
Warning +
RIDE: SPORT
Warning +
RIDE: NORMAL
Warning +
RIDE: COMFORT
Warning +
HEIGHT: HIGH
Warning +
HEIGHT: NORMAL
Warning +
HEIGHT: LOW
Slow or Fast Blinking
Warning Light
Condition Cause
Battery Voltage in excess of
16VDC
Vehicle charging system providing incorrect voltage.
LiquidSpring system not connected to 12VDC electrical system
See
Issues with Vehicle Raising/Pump Section
Pump Motor runs in excess of
3 minutes
Battery Voltage below 9 VDC Vehicle charging system providing incorrect voltage
Low vehicle battery
See
Issues with Height Sensors Section
Issue with Right Hand Height
Sensor
System kneels in excess of 3 minutes without suspension movement
Issue with Left Hand Height
Sensor
See
See
Issues with Vehicle Lowering/Dump Valve
Section
Issues with Height Sensors Section
Driver Interface can not communicate with ECU.
Issues with Vehicle Raising/Pump
Condition Cause
Vehicle Leveled, Pump continues to run Pump motor shorted out.
Software issue
Excessive noise in height sensor
Vehicle Not Leveled (or Raised), Pump runs
Reservoir fluid level low
Hydraulic leak in system
Vehicle overloaded
Air in pump
Vehicle Not Leveled (or Raised), Pump does not run
Pump runs for short time then stops
Pump runs intermittently
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
Correction
Inspect and replace as necessary.
Inspect and replace as necessary
See
Issues with Vehicle Raising/Pump 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 Height Sensors Section
Correction
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.
Issues with Vehicle Lowering/Dump Valve
Condition
Vehicle does not lower (kneel).
Vehicle slow lowering (kneeling)
Cause
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
Correction
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
30
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
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
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
Cause
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 No Height Sensor Signal change while driving
Issues with Ride/Handling
Condition
Vehicle rolls side to side excessively
Excessive stiffness when on flat, straight road
Correction
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
Correction
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.
Cause Correction
System inactive (Drivers interface dark) Turn system on (press On/Off button)
No electrical power to system
Strut bushings worn
Inspect and replace as necessary
Inspect and replace as necessary
Control arm bushings worn
Sway bar bushings worn
Strut mounting loose
Rate Valve wiring shorted, broken, or disconnected
Inspect and replace as necessary
Inspect and replace as necessary
Inspect and replace as necessary
Inspect wiring and correct/replace as necessary.
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
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
Steering sensor wiring broke or incorrect.
Steering sensor malfunction
Steering sensor not installed correctly
Zero point of steering sensor incorrect.
Loose connector / wire
Correction
Inspect wiring to steering sensor and correct as necessary.
Replace sensor
Inspect installation and correct as necessary
See
Calibrating the Steering Sensor Only.
Check wiring between Steering sensor and Power module for loose connection.
31
Issues with Vehicle Speed Signal
Condition
System leveling excessively while driving.
Intermittent speed sensor signal
Cause
Speed Sensor wiring shorted, broken, or disconnected
Speed signal malfunction
Loose connector / wire
Correction
Inspect wiring and repair/replace as necessary
Issues with Vehicle Brake Signal
Condition
Vehicle will not level
Intermittent leveling
Issues with Door Switch
Condition
Vehicle will not kneel when rear door opened
Cause
Brake signal wire not correctly tapped.
Brake switch malfunction
Loose connector / wire
Vehicle kneels whenever speed below
5mph
Intermittent door switch signal
Issues with Vehicle Ignition Signal
Condition
System does not turn on (no leveling or stiffness control)
Cause
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
Cause
No ignition signal to controller or driver interface
Ignition "sensor" malfunction
Signal side short to battery
Ignition "sensor" malfunction
Loose connector / wire
System does not turn off once ignition switched off
System intermittently works
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
Issues with Driver Interface
Condition
Warning light blinks, system appears to level.
Warning light blinks, system does not appear to operate (level)
Cause
No park signal to controller
Park sensor malfunction
Park signal always on
Park sensor malfunction
Loose connector / wire
Cause
Correction
Inspect wiring and repair/replace as necessary.
Replace OEM speed sensor. See OEM service manual.
Inspect wiring and repair/replace as necessary.
Correction
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.
Correction
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.
Correction
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.
Correction
CAN wires crossed or not connected.
Malfunctioning Driver Interface
No power to ECU (5A 18ga Red Wire)
Inspect wiring and repair/replace as necessary.
Inspect and replace as necessary.
Inspect wiring and repair/replace as necessary.
No ignition signal to ECU (Yellow Wire) Inspect wiring and repair/replace as necessary.
CAN wires crossed or not connected. 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.
32
Issues with Power Module
Condition
Pump exhibits high pitch whine immediately after pump stops or when vehicle lowering
Pump running under heavy load and leveling slow
Pump running under heavy load and no leveling
Hydraulic fluid leaking from Power
Module
Cause
The Check Valve is stuck open
The Check Valve is only partially open
The Check valve is stuck closed
Replace Power Module
Replace Power Module
Replace Power Module
Correction
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
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
Replace strut
Replace strut
Replace strut
Correction
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
33
Issues with Secondary Volume Assembly
Condition
Hydraulic Leak loose or no longer attached
Cause Correction
Weld failure between tube and end Replace secondary volume welded assembly
Weld failure between tube and manifold Replace secondary volume welded assembly
Cylinder fracture
Bleed screw loose
Replace secondary volume welded assembly
Tighten bleed screws to appropriate torque
Fitting loose
Hose failure
Hose cut
Bolts attaching bracket to frame broken / came out
Tighten all fittings
Replace failed hose
Replace failed hose
Replace bolts and tighten to required torque
Bolt attaching volumes to bracket broke / came out
Weld Failure
Structural failure
Replace bolts and tighten to required torque
Replace brackets
Replace brackets
34
Appendix A: Electrical Schematics
35
36
37
38
CLASS
®
Product Limited
Warranty
L
IQUID
WWW
S
PRING
TM LLC
3416 RASCAL DRIVE
LAFAYETTE, IN 47909
PH: 765-474-7816, FAX: 765-474-
7826
.
LIQUIDSPRING
.
COM
Warranty Conditions
LiquidSpring LLC warrants that all
CLASS
®
products shall be free of defects in material and workmanship provided the product has been properly assembled, installed by a designated/qualified installer, properly maintained, serviced, and used normally for the given application and within the rated capacities. The end user is responsible for operating, inspecting, and maintaining the product according to applicable product and vehicle owner’s manuals and for instructing all operators and maintenance personnel on proper use and maintenance.
Coverage
The starting date for warranty coverage will be the earlier date of the date purchased by the first end user or when the vehicle is put into service and ends when the time period is reached in the warranty coverage period below. Proof of such date is the responsibility of the first end user. If the starting date cannot be satisfactorily determined, then the date of product manufacture based on the product serial number shall be used as the effective starting date.
Main Structural Components –
48 Months or 100,000 miles whichever occurs first.
Major structural components are defined as frame hangers, control arms, axle clamp group, transverse torque arm axle and frame mounts, struts, and secondary volumes. All wear items such as bushings are excluded.
Other Components –
36 Months or 50,000 miles whichever occurs first.
Other components include all power module components, electrical harnesses, spring rate valves, hydraulic lines, and wear items such as bushings and seals.
Labor –
12 Months
Estimated labor time and cost must be pre-approved prior to conducting warranty repair work for reimbursement consideration.
Claims
1.
Review warranty conditions and coverage to determine if component is warrantable.
2.
Locate product serial number, warranty starting date (see Coverage above), vehicle manufacturer, mileage, and VIN.
3.
Contact LiquidSpring LLC to address claim.
Components must be returned to LiquidSpring LLC
Prepaid
and identified with a LiquidSpring LLC issued Returned
Goods Authorization Number (RGA#) in order to qualify for reimbursement by LiquidSpring LLC. LiquidSpring LLC must authorize all warranty repairs at a cost determined and approved by LiquidSpring LLC
before any repairs are started
.
Warranty Contact:
(765) 474-7816 [email protected]
Limitations and Exclusions
The liability of LiquidSpring LLC under this limited warranty is solely limited to the repair or replacement of defective material and workmanship by an authorized party. LiquidSpring LLC shall not be liable for use of non-LiquidSpring LLC components or for repairs performed by unauthorized parties. This warranty does not include any expense of or related to transportation of parts outside the Continental United States or compensation for inconvenience or loss of use while the product is being repaired. LiquidSpring LLC shall not be liable for any expense, loss, or damage (direct, incidental, consequential or exemplary – including, but not limited to towing expenses, travel expenses, vehicle rental, downtime expenses, incidental charges or any other losses arising in connection with the sale, use or inability to use the product) resulting from the warrantycovered component found to be defective.
No expressed warranty is given by LiquidSpring LLC with respect to its product except at specifically set forth herein. Any warranty implied by law, including any warranty of merchantability or fitness for particular purpose, is limited to the expressed warranty term provided in the warranty coverage. The expressed warranty does not apply in the event of: use of non-
February 2016 D10825 Rev.E
CLASS
®
Product Limited
Warranty
L
IQUID
WWW
S
PRING
TM LLC
3416 RASCAL DRIVE
LAFAYETTE, IN 47909
PH: 765-474-7816, FAX: 765-474-
7826
.
LIQUIDSPRING
.
COM
LiquidSpring LLC replacement components; improper installation, maintenance or repair; misuse, negligence, or abuse including but not limited to overloading, unauthorized alterations or modifications.
Warranty Labor Coverage
ALLOWABLE
LABOR HOURS (*)
COMPONENT
One Strut
Pair of Struts
Power module
Pressure relief valve
ECU (External)
ECU (Internal)
Height / Steering Sensor
Rate Valve
Track Rod Bushing
One Control Arm
0.50
0.75
0.50
1.00
1.50
1.50
0.75
1.50
1.00
0.50
Pair of Control Arm 2.00
(FOR ANY COMPONENT(s) NOT LISTED ABOVE, THE ALLOWABLE LABOR HOURS MUST BE APPROVED BY
LIQUIDSPRING LLC.
PRIOR TO THE WORK BEING PREFORMED.)
*LABOR HOURS BASED ON $85.00 PER HOUR.
*LABOR FOR DIAGNOSIS WILL NOT BE COVERD WITHOUT PRIOR CONSENT FROM
LIQUIDSPRING LLC.
Obtaining Warranty Parts
1.
Obtain
LiquidSpring LLC
suspension serial number
(Located on driver’s side front hanger see Operator’s Manual for details)
2.
Obtain mileage of suspension
3.
Obtain In-service date of suspension
4.
Give a detailed description of the problem
Contact LiquidSpring LLC
February 2016
Service Dept.
Phone: 765-474-7816
Email: [email protected]
D10825 Rev.E
DS129FS3 - DS147FS3/B
Installation Check List
Installer:
Inspector:
Installation Date:
Inspection Date:
Suspension S/N: VIN:
FRAME PREPARATION:
☐
Battery Disconnected
☐
Removed OEM Leaf springs, overload pads, and Driver side shock mount.
☐
Upper Strut Mount, and Secondary Volume Assy holes drilled.
BRAKE LINES.
☐
Replaced OEM flexible brake lines, and axle standoff bracket with provided parts.
☐
Torqued Brake line tube fittings to
159 in-lbs
.
☐
Torqued Brake line banjo bolts to
35 ft-lbs
.
☐
Brake system bled and bleed screws torqued to
133 in-lbs
.
FRONT HANGER INSTALLATION:
☐
Front Hangers are flush to bottom of frame and OEM M14 Flange bolts torqued to 120-145 ft-lbs.
☐ 5/8”-11 Nuts torqued to
-172-210 ft-lbs
.
UPPER STRUT MOUNT/TRACK ROD MOUNT / CROSS MEMBER REINFORCEMENT
:
☐
Upper Strut Mounts level with frame.
☐
Cross member Reinforcement orientated correctly.
☐
Bolts point outboard, away from fuel tank.
☐
5/8”-11 Nuts torqued to
-172-210 ft-lbs
.
☐
1/2”-13 Nuts torqued to
86-105 ft-lbs
.
AXLE CLAMP / BRIDGE INSTALLATION:
☐
3/4”-16 U-Bolts torqued in stages up to
250 ft-lbs
.
CONTROL ARMS INSTALLATION:
☐ 1”-8 Nuts torqued to
600 ft-lbs
, at ride height.
TRACK ROD INSTALLATION:
☐ 7/8”-9 Nuts Torqued to
491-600 ft-lbs
.
STRUT INSTALLATION:
☐
3/4”-10 Upper Nuts torqued to
275-300 ft-lbs
.
☐ 3/4”-10 Lower Nuts torqued to
275-300 ft-lbs
.
HEIGHT SENSOR INSTALLATION:
☐
5/16”-18 Nuts torqued to
14-17 ft-lbs
.
☐
Linkage Locks installed.
POWER MODULE/SECONDARY VOLUME INSTALLATION:
☐ 3/8”-16 Screws torqued to
39 ft-lbs
.
☐
Reservoir Mount Self Tapping Screws tightened to
snug only
.
☐ 5/16”-24 T-Bolt Band Clamp Fasteners torqued to
240 in-lbs
.
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 Nuts torqued to
14-17 ft-lbs
.
41
DS129FS3 - DS147FS3/B
PARKING BRAKE CABLE INSTALLATION:
☐
Parking Brake Cable Mount installed, and 1/2” Fasteners torqued to
86-105 ft-lbs.
☐
Passenger side Cable secured to bridge standoffs.
☐
Driver and Pass OEM cable guides attached to Parking Brake Cable Mount and 5/16” fasteners torqued to
14-17 ft-lbs
.
STEERING SENSOR INSTALLATION:
☐
OEM Nuts torqued to
120-147 ft-lbs.
☐
5/16”-18 fasteners torqued to
14-17 ft-lbs.
☐ 1/4”-20 U-bolt nuts torqued to
60-85 in-lbs.
☐
Linkage Lock installed on sensor side.
☐
Steering sensor harness attached and routed.
☐
Steering wheel turned full left and full right and checked for clearance around sensor and linkage.
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.
☐
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.
☐
System Bled and Bleed Screws closed and torqued to
13-18 ft-lbs
☐
Calibration completed.
42
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