Air Lift LoadLifter 5000 Ultimate air helper springs Installation Guide
Below you will find brief information for air helper springs LoadLifter 5000 Ultimate. The LoadLifter 5000 Ultimate uses sturdy, reinforced, commercial grade single or double, depending on the kit, convolute bellows. The bellows are manufactured like a tire with layers of rubber and cords that control growth. An internal jounce bumper inside the spring absorbs shock and eliminates harsh jarring on rough roads. The internal jounce bumper replaces the factory bumper and allows the air springs to safely be run at zero air pressure. The LoadLifter 5000 Ultimate kits are recommended for most ¾ and 1 ton pickups and SUVs with leaf springs and provide up to 5,000 lbs. of load leveling support with air adjustability from 5-100 PSI. The kits are also used in motorhome rear kits and some motorhome fronts where leaf springs are used.
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A D J U S TA B L E A I R H E L P E R S P R I N G S
TOW AND HAUL WITH SAFETY AND COMFORT
TM
Kit Number
88242
INSTALLATION GUIDE
For maximum effectiveness and safety, please read these instructions completely before proceeding with installation.
Failure to read these instructions can result in an incorrect installation.
MN-850 • (021306) • ECR 7678
LoadLifter 5000 Ultimate
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware and Tools Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the LoadLifter 5000 Ultimate System . . . . . . . . . . . . . . . 5
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Raising the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembling the Air Spring Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attaching the Air Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking the Air Spring Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fixing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Use, Maintenance and Servicing . . . . . . . . . . . . . . . . . . . 12
Minimum Recommended Pressure and Maximum Pressure . . . . . . . . . . . . . . . . . . . . 12
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tuning the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Guidelines for Adding Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Choosing the Right On-Board Air Compressor System . . . . . . . 15
Warranty and Returns Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MN-850
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2
LoadLifter 5000 Ultimate
Introduction
The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the LoadLifter 5000 Ultimate air spring kit. LoadLifter 5000 Ultimate utilizes sturdy, reinforced, commercial grade single or double, depending on the kit, convolute bellows. The bellows are manufactured like a tire with layers of rubber and cords that control growth. An internal jounce bumper inside the spring absorbs shock and eliminates harsh jarring on rough roads. The internal jounce bumper replaces the factory bumper and allows the air springs to safely be run at zero air pressure. LoadLifter 5000 Ultimate kits are recommended for most ¾ and 1 ton pickups and SUVs with leaf springs and provide up to 5,000 lbs. of load leveling support with air adjustability from 5-100 PSI. The kits are also used in motorhome rear kits and some motorhome fronts where leaf springs are used.
It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information here includes a hardware list, tool list, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide.
Air Lift Company reserves the right to make changes and improvements to its products and publications at any time. For the latest version of this manual, contact Air Lift Company at
(800) 248-0892 or visit our website at www.airliftcompany.com.
IMPORTANT SAFETY NOTICE
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load listed for your vehicle.
Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle
(including passengers and cargo). This number — along with other weight limits, as well as tire, rim size and inflation pressure data — is shown on the vehicle’s Safety Compliance
Certification Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide.
DANGER
WARNING
CAUTION
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
TO THE MACHINE OR MINOR PERSONAL INJURY.
NOTE
Indicates a procedure, practice or hint which is important to highlight.
MN-850
LoadLifter 5000 Ultimate
Installation Diagram
PLEASE READ THESE INSTRUCTIONS COMPLETELY BEFORE PROCEEDING WITH INSTALLATION
E
F
G
H
J
K
I
Outboard
L
A
D
B
Forward
D
C
L
fig. 1
M
M
H
K
H
G
F
H
K
IMPORTANT: Check both sides of the frame rail for any interference or obstructions
(specifically, propane lines) that may prevent install the air springs on the outside of the frame rail. If obstructions are present, use kit 57131, which mounts under the frame to the axle.
MN-850
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Hardware and Tools Lists
HARDWARE LIST
Item Part # Description ............................... Qty
A 58494
B 07475
C 03102
Air Spring ............................................2
Upper Bracket .....................................2
Lower Bracket .....................................2
D 11967
E 21837
F 17203
G 18427
H 18444
I 17159
J 18447
K 18435
L 17163
M 01426
Roll Plate .............................................4
Air Fitting .............................................2
3/8”-24 X 7/8” Bolt ...............................8
3/8” Lock Washer ................................8
3/8” Flat Washer, SAE .......................16
3/8”-16 X 1.5” Frame Bolt ...................8
3/8” Oversized Flat Washer ................8
3/8”-16 Nylock Nut .............................16
3/8”-16 X 7” Carriage Bolt ...................8
Clamp/Spacer Bar ...............................8
AA 20086sub Air Line Assembly ...............................1
BB 10466
CC
DD
EE
21230
18405
21234
Tie Strap .............................................6
Valve Cap ...........................................2
5/16” Flat Washer ...............................2
Rubber Washer ...................................2
FF 18411
GG 21233
Star Washer ........................................2
5/16” Hex Nut ......................................4
TOOLS LIST
Description
1/2 “, 9/16 “ open-end or box wrenches
Crescent Wrench
Ratchet with 9/16 “ and 1/2 “ deep well sockets
5/16 “ drill bits (very sharp)
Heavy Duty Drill
Torque Wrench
Hose Cutter, Razor Blade, or Sharp Knife
Hoist or Floor Jacks
Safety Stands
Safety Glasses
Air Compressor, or Compressed Air Source
Spray Bottle with Dish Soap/Water Solution
LoadLifter 5000 Ultimate
4
STOP!
Missing or damaged parts? Call Air Lift customer service at (800) 248-0892 for a replacement part.
MN-850
LoadLifter 5000 Ultimate
Installing the LoadLifter 5000 Ultimate System
IMPORTANT: The vehicle may be equipped with a rear brake proportioning valve. Any type of load assist product could affect brake performance. We recommend that you check with your dealer before installing this type of product. If the vehicle DOES NOT have a rear brake proportioning valve or is equipped with an anti-lock type brake system, installation of a load assist product will have NO EFFECT ON BRAKE SYSTEM PERFORMANCE.
IMPORTANT: Check both sides of the frame rail for any interference or obstructions
(specifically, propane lines) that may prevent install the air springs on the outside of the frame rail. If obstructions are present, use kit 57131, which mounts under the frame to the axle.
DANGER
COMPRESSED AIR CAN CAUSE INJURY AND DAMAGE TO THE VEHICLE AND PARTS
IF IT IS NOT HANDLED PROPERLY. FOR YOUR SAFETY, DO NOT TRY TO INFLATE
THE AIR SPRINGS UNTIL THEY HAVE BEEN PROPERLY SECURED TO THE VEHICLE.
GETTING STARTED
1. Determine the Normal Ride Height. The Normal Ride Height is the distance between the bottom edge of the wheel-well and the center of the hub with the vehicle in the “as delivered” condition. In some cases, Normal Ride Height is not perfectly level.
a. Remove unusual loads and examine your vehicle from the side to ensure it is on a level surface. b. If necessary (in cases where the leaf springs are sagging badly), use a jack to raise the rear end so that the vehicle achieves the original “as delivered” ride height.
2. Measure the distance between the center of the hub and the bottom edge of the wheel well (see Figure 2). This is the Normal Ride Height. Enter the measurement below:
NORMAL RIDE HEIGHT: __________ inches
3. Measure the distance between the frame and the tire. This kit requires a minimum of
7.5” of clearance for a fully inflated air spring (Figure 3).
NOTE: The measurement from one end of the arrow to the other end is the Normal
Ride Height.
fig. 2 fig. 3
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LoadLifter 5000 Ultimate
RAISING THE VEHICLE
1. Raise the vehicle and remove the wheels.
2. Check the distance between the center of the hub and the bottom edge of the wheel to ensure that it is at the normal ride height recorded above. If not, raise the frame or lower the axle as necessary to restore the original distance.
a. If the vehicle is raised with an axle contact hoist, then place axle stands under the frame and lower the axle as needed.
b. If the vehicle is raised with a frame contact hoist, then place axle stands under the axle and lower the frame as needed.
c. If the vehicle is raised with a jack and supported with axle stands on the frame, then use a floor jack to lower the axle.
ASSEMBLING THE AIR SPRING UNIT
1. Place a roll plate (D) on the top and bottom of the air spring (A) so that the air spring is seated within the roll plates (Figure 4).
fig. 4
2. Install the air fitting (E) finger tight plus 1
1
/
2
turns (Figure 4). Use a
7
/
16
” open end wrench, being careful to tighten on the metal hex nut only. Do not overtighten. This fitting is precoated with sealant.
3. Attach the upper bracket (B) with the legs down using two flat washers (H), two lock washers (G), and two bolts (F). Refer to Figure 1. Leave loose for adjustment.
4. Place the lower bracket (C) on to the bottom of the air spring and roll plate so that the flat edge of the lower bracket mounts towards the legs of the upper bracket (inboard).
Refer to Figure 1.
5. Attach the lower bracket to the air spring assembly using two flat washers (H), two lock washers (G), and two bolts (F). Refer to Figure 1. Leave loose for adjustment.
ATTACHING THE AIR SPRING ASSEMBLY
1. Set the assembly on the leaf spring over the axle. The upper and lower brackets must be positioned with 4.5” to 6.5” between the brackets at normal ride height (Figure 5).
Distance from upper to lower bracket MUST be within the ranges of 4.5" to 6.5"
fig. 5
MN-850
LoadLifter 5000 Ultimate
NOTE
NOTE
If the measurement is not within the specified parameters or if the stock u-bolts hit on the lower bracket, use two spacer bars (M) provided under the lower bracket to achieve the distance of 4.5” to 6.5” (Figure 1).
2. Position the upper bracket so that at least four bolt holes (two on each side) are on the flat section of the frame rail. Use the widest spacing possible to achieve the required distance of 4.5” to 6.5” making sure that the holes do not fall on the radiused edges of the frame rail.
3.
4. Attach the lower bracket using two clamp bars (M), four carriage bolts (L), four flat washers (H), and four nylock nuts (K). Refer to Figure 1. Tighten securely.
5.
6. Position the upper bracket as high on the frame as possible and so that it is parallel with the lower bracket. If the correct mounting height can not be achieved with the top hole and one of the two lower holes, then position the top holes above the frame and use the two sets of lower holes for mounting. Align the assembly both vertically and horizontally. Be sure that there is sufficient clearance between the air spring, the frame, the tire and brake drum at the maximum inflated diameter (6.5”).
The kit will be mounted on the same angle as the leaf springs.
7. Clamp the upper bracket to the frame rail with a C-clamp or welding clamp and center punch one mounting hole (Figure 6).
MN-850
fig. 6
IMPORTANT: Do not drill any holes into the frame without first checking for interference such as hydraulic lines, gas lines, and/or electrical wires. If there are any such interferences, move them aside to proceed with the installation.
8. Check the upper to lower bracket measurement to ensure that it is still between 4.5” to
6.5” on the side of the center punched hole (in Figure 7, measurement X must equal measurements Y, as well as between 4.5” to 6.5”).
X Y
fig. 7
9. Drill one
3
/
8
” hole in the previously marked location and loosely install a frame bolt (I), an oversized flat washer (J), and a nylock nut (K).
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LoadLifter 5000 Ultimate
1. Measure the upper to lower bracket clearance on the other side of the upper bracket.
This measurement should be equal to the measurement of the other side of the upper bracket (in Figure 7, measurements X must equal measurement Y, as well as be between 4.5” to 6.5”).
2. Center punch and drill a hole on the other side of the upper bracket and install a frame bolt (I), an oversized flat washer (J), and a nylock nut (K). Refer to Figure 1.
3. Remove the clamps and drill the remaining two holes and install a frame bolt (I), an oversized flat washer (J), and a nylock nut. Tighten all upper bracket hardware to 44 ft-lbs.
CHECKING AIR SPRING ALIGNMENT
1. With the air spring hardware still loose, align the air spring inboard and outboard using the slotted holes for adjustment so that it is uniformly positioned between the brackets
(Figure 8).
fig. 8
NOTE
NOTE
8
CAUTION
Maintain at least a thumb’s width of clearance between the air spring and frame when uninflated.
2. When fully aligned, secure the air spring to the upper and lower brackets by tightening the mounting hardware with a
9
/
16
” wrench. Tighten securely.
INSTALLING THE AIR LINES
1. Choose a convenient location for mounting the inflation valves. Popular locations for the inflation valve include: wheel well flanges, license plate recess in bumper, under the gas cap access door, or through license plate itself.
What ever the chosen location is, make sure there is enough clearance around the inflation valves for an air chuck.
2. Drill a
5
/
16
“ hole to install the inflation valves.
3. Cut the air line assembly (AA) in two equal lengths.
WHEN CUTTING OR TRIMMING THE AIR LINE, USE A HOSE CUTTER (AIR LIFT P/N
10530), A RAZOR BLADE OR A SHARP KNIFE. A CLEAN, SQUARE CUT WILL ENSURE
AGAINST LEAKS. DO NOT USE WIRE CUTTERS OR SCISSORS TO CUT THE AIR
LINE. THESE TOOLS MAY FLATTEN OR CRIMP THE AIR LINE, CAUSING IT TO LEAK
AROUND THE O-RING SEAL INSIDE THE ELBOW FITTING.
4. Place a
5
/
16
“ nut (GG) and a star washer (FF) on the air valve. Leave enough of the inflation valve in front of the nut to extend through the hole and have room for the rubber washer (EE), flat washer (DD), and
5
/
16
“ nut (GG) and cap (CC). There should be enough
MN-850
LoadLifter 5000 Ultimate
valve exposed after installation - approximately
1
/
2
“ - to easily apply a pressure gauge or an air chuck (Figure 9).
5. Push the inflation valve through the hole and use the rubber washer (EE), flat washer
(DD), and another
5
/
16
“ nut (GG) to secure it in place. Tighten the nuts to secure the assembly in place (Figure 9).
fig. 9
6. Route the air line along the frame to the air fitting on the air spring. Keep at least 6” of clearance between the air line and heat sources, such as the exhaust pipes, muffler, or catalytic converter. Avoid sharp bends and edges. Use the plastic tie straps (BB) to secure the air line to fixed, non-moving points along the chassis. Be sure that the tie straps are tight, but do not pinch the air line (Figure 10).
MN-850
fig. 10
7. Cut off air line leaving approximately 12” of extra air line. A clean square cut will ensure against leaks. Insert the air line into the air fitting. This is a push to connect fitting.
Simply push the air line into the air fitting until it bottoms out (
9
/
16
” of air line should be in the fitting).
8. Install the minimum/maximum air pressure decal in a highly visable location, such as the driver’s side window just above the door handle.
9. Return to the beginning of the manual and install the remaining air spring on the other side.
CHECKING FOR LEAKS
1. Inflate the air spring to 60 PSI.
2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and
4/5 water. Spot leaks easily by looking for bubbles in the soapy water.
3. After the test, deflate the springs to the minimum pressure required to restore the system to normal ride height. Do not deflate to lower than 10 PSI.
4. Check the air pressure again after 24 hours. A 2 - 4 PSI loss after initial installation is
9
10
CAUTION
LoadLifter 5000 Ultimate
normal. Retest for leaks if the loss is more than 5 lbs.
FIXING LEAKS
1. If there is a problem with the swivel fitting: a. Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line. Trim 1” off the end of the air line. Be sure the cut is clean and square. Reinsert the air line into the pushto-connect fitting.
b. Check the threaded connection by tightening the swivel fitting another ½ turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. Reinstall by hand tightening as much as possible and then use a wrench for an additional two turns.
2. If there is a problem with the inflation valve: a. Check the valve core by tightening it with a valve core tool.
b. Check the air line by removing the air line from the barbed type fitting. Cut the air line off a few inches in front of the fitting and use a pair of pliers or vice grips to pull/ twist the air line off of the fitting.
DO NOT CUT OFF THE AIR LINE COMPLETELY AS THIS WILL USUALLY NICK THE
BARB AND RENDER THE FITTING USELESS.
3. If the preceding steps have not resolved the problem, call Air Lift customer service at
(800) 248-0892.
1.
MN-850
LoadLifter 5000 Ultimate
Before Operating
INSTALLATION CHECKLIST
(To be completed by installer)
Clearance test — Inflate the air springs to 60 PSI and ensure there is at least ½” clearance around each bellow, away from anything that might rub against them. Be sure to check the tire, brake drum, frame, shock absorbers and brake cables.
Leak test before road test — Inflate the air springs to 60 PSI, check all connections for leaks with a soapy water solution. See page 9 for tips on how to spot leaks. All leaks must be eliminated before the vehicle is road tested.
Heat test — Be sure there is sufficient clearance from any heat sources — at least 6” for air springs and air lines. If a heat shield was included in the kit, install it. If there is no heat shield, but one is required, call (800) 248-0892.
Fastener test — Recheck all bolts for proper torque. Axle clamp bar carriage bolt lock nuts should be torqued to 16 ft/lbs. Re-torque after 100 miles.
Road test — The vehicle should be road tested after the preceding tests. Inflate the air springs to 25 PSI (50 PSI if the vehicle is loaded). Drive the vehicle 10 miles and recheck for clearance, loose fasteners and air leaks.
Operating instructions — If professionally installed, the installer should review the Product
Use, Maintenance and Servicing section on page 12 with the owner. Be sure to provide the owner with all of the paperwork which came with the kit.
Technician’s Signature ________________________
Date ______________
POST-INSTALLATION CHECKLIST
Overnight leak down test — Recheck air pressure after the vehicle has been used for
24 hours. If the pressure has dropped more than 5 PSI, then there is a leak that must be fixed. Either fix the leak yourself or return to the installer for service.
Air pressure requirements — Regardless of load, the air pressure should always be adjusted to maintain ride height at all times.
Thirty day or 500 mile test —Recheck the air spring system after 30 days or 500 miles, whichever comes first. If any part shows signs of rubbing or abrasion, the source should be identified and moved, if possible. If it is not possible to relocate the cause of the abrasion, the air spring may need to be remounted. If professionally installed, the installer should be consulted. Check all fasteners for tightness.
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LoadLifter 5000 Ultimate
Product Use, Maintenance and Servicing
Minimum Recommended Pressure
20 PSI
Maximum Air Pressure
100 PSI
NOTE
CAUTION
MAINTENANCE GUIDELINES
By following the steps below, vehicle owners will obtain the longest life and best results from their air springs.
1. Check the air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI.
3. If you develop an air leak in the system, use a soapy water solution (1/5 liquid dish soap and 4/5 water) to check all air line connections and the inflation valve core before deflating and removing the air spring.
FOR YOUR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO YOUR VEHICLE, DO
NOT EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR), AS INDICATED
BY THE VEHICLE MANUFACTURER. ALTHOUGH YOUR AIR SPRINGS ARE RATED AT
A MAXIMUM INFLATION PRESSURE OF 100 P.S.I., THE AIR PRESSURE ACTUALLY
NEEDED IS DEPENDANT ON YOUR LOAD AND GVWR.
4. Loaded vehicles require at least 25 PSI or more. A “loaded vehicle” refers to a vehicle with a heavy bed load, a trailer, or both. As discussed above, never exceed GVWR, regardless of air spring, air pressure, or other load assist. The springs in this kit will support approximately 40 lbs. of load (combined on both springs) for each 1 PSI of pressure.
The required air pressure will vary depending on the state of the original suspension.
Operating the vehicle below the minimum air spring pressure will void the Air Lift warranty.
5. When increasing load, always adjust the air pressure to maintain the normal ride height.
Increase or decrease pressure from the system as necessary to attain normal ride height for optimal ride and handling. Remember that loads carried behind the axle (including tongue loads) require more leveling force (pressure) than those carried directly over the axle.
6. Always add air to springs in small quantities, checking the pressure frequently.
7. Should it become necessary to raise the vehicle by the frame, make sure the system is at minimum pressure (5 PSI) to reduce the tension on the suspension/brake components.
Use of on board leveling systems do not require deflation or disconnection.
8. Periodically check the air spring system fasteners for tightness. Also, check the air springs for any signs of rubbing. Realign if necessary.
9. On occasion, give the air springs a hard spray with a garden hose in order to remove mud, sand, gravel or other abrasive debris.
TROUBLESHOOTING GUIDE
1. Leak test the air line connections, the threaded connection into the air spring, and all fittings in the control system.
2. Inspect the air lines to be sure none are pinched. Tie straps may be too tight. Loosen or replace the strap and replace leaking components.
3. Inspect the air line for holes and cracks. Replace as needed.
4. Look for a kink or fold in the air line. Reroute as needed.
12
MN-850
LoadLifter 5000 Ultimate
If the preceding steps do not solve the problem, it is possibly caused by a failed air spring — either a factory defect or an operating problem. Please call Air Lift at (800) 248-0892 for assistance.
FREQUENTLY ASKED QUESTIONS
Q. Will installing air springs increase the weight ratings of a vehicle?
No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR) of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty.
Q. Is it necessary to keep air in the air springs at all times and how much pressure will they need?
For LoadLifter 5000 Ultimate, the recommended minimum air pressure is 5 PSI, but it can safely be run at zero air pressure.
Q. Is it necessary to add a compressor system to the air springs?
No. Air pressure can be adjusted with any type of compressor as long as it can produce sufficient pressure to service the springs. Even a bicycle tire pump can be used, but it’s a lot of work.
Q. How long should air springs last?
If the air springs are properly installed and maintained they can last indefinitely.
Q. Will raising the vehicle on a hoist for service work damage the air springs?
No. The vehicle can be lifted on a hoist for short-term service work such as tire rotation or oil changes. However, if the vehicle will be on the hoist for a prolonged period of time, support the axle with jack stands in order to take the tension off of the air springs.
TUNING THE AIR PRESSURE
Pressure determination comes down to three things — level vehicle, ride comfort, and stability.
1. Level vehicle
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side, then it is not level (fig. 2.1). Raise the air pressure to correct either of these problems and level the vehicle.
2. Ride comfort
If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough (fig. 2.2). Try different pressures to determine the best ride comfort.
3. Stability
Stability translates into safety and should be the priority, meaning the driver may need to sacrifice a perfectly level and comfortable ride. Stability issues include roll control, bounce, dive during braking and sponginess (fig. 2.3). Tuning out these problems usually requires an increase in pressure.
MN-850
Bad headlight aim
fig. 2.1
Rough ride
fig. 2.2
Sway and body roll
fig. 2.3
13
14
LoadLifter 5000 Ultimate
GUIDELINES FOR ADDING AIR
1. Start with the vehicle level or slightly above.
2. When in doubt, always add air.
3. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
4. If it is ever suspected that the air bags have bottomed out, increase the pressure (fig. 2.4).
5. Adjust the pressure up and down to find the best ride.
6. If the vehicle rocks and rolls, adjust the air pressure to reduce movement.
7. It may be necessary to maintain different pressures on each side of the vehicle. Loads such as water, fuel, and appliances will cause the vehicle to be heavier on one side (fig.
2.5). As much as a 50 PSI difference is not uncommon.
Bottoming out
fig. 2.4
Unlevel Level
fig. 2.5
MN-850
LoadLifter 5000 Ultimate
Choosing the Right On-Board Air Compressor System
Add an on-board air compressor sytem to inflate and deflate your air springs with the touch of a button — from inside or outside of the vehicle.
• For convenient, on-the-go control of your air springs, add an Air Lift on-board air compressor system.
• Air Lift on-board air compressor systems eliminate the search for gas stations that have a working compressor, saving you time, energy and money.
• All systems include a compressor, controller and all parts needed for easy installation.
1. Choose single or dual path inflation (see illustrations at right)
2. Choose wireless or analog control
• Wireless: Control your air springs from inside or outside the vehicle. Easiest installation - no wires to the cab.
• Analog: In-cab control of your air springs.
Economically priced.
Dual path systems Air springs are controlled separately to allow for different air pressure from side-to-side. Perfect for uneven or top-heavy loads.
3. Choose heavy or standard duty compressor
• Standard duty: A standard duty compressor will work well for most customers who use their system on an intermittent basis.
• Heavy duty: For daily use, consider the heavy duty compressor - it inflates faster and more quietly than the standard compressor.
Visit www.airliftcompany.com for more detailed info on compressor systems.
W I R E L E S S
WirelessAIR
TM
• Easy installation
• Includes heavy duty compressor
P/N 72000
Single path systems Two springs will inflate at the same time. Good for loads that are evenly distributed from left-toright or front-to-back.
A N A L O G
LoadCONTROLLER
Dual
TM
Compact, economically priced control.
P/N Standard Duty Compressor
DEFLATE
LEFT
25850; P/N Heavy Duty mpressor 25854
INFLATE
BOTH
DEFLATE
RIGHT
WirelessONE
TM
• Easy installation
• Includes standard duty compressor
P/N 25870
LoadCONTROLLER
TM
Single
Compact, economically priced control.
P/N Standard Duty Compressor
DEFLATE
BOTH
INFLATE
BOTH
25852; P/N Heavy Duty Compressor 25856
MN-850
15
LoadLifter 5000 Ultimate
Warranty and Returns Policy
Air Lift Company warrants its products, for the time periods listed below, to the original retail purchaser against manufacturing defects when used on catalog-listed applications on cars, vans, light trucks and motorhomes under normal operating conditions for as long as
Air Lift manufactures the product. The warranty does not apply to products that have been improperly applied, improperly installed, used in racing or off-road applications, used for commercial purposes, or which have not been maintained in accordance with installation instructions furnished with all products. The consumer will be responsible for removing
(labor charges) the defective product from the vehicle and returning it, transportation costs prepaid, to the dealer from which it was purchased or to Air Lift Company for verification.
Air Lift will repair or replace, at its option, defective products or components. A minimum
$10.00 shipping and handling charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-0892 in the U.S. and Canada
(elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.
Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI •
48917.
Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product, loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible for installation/reinstallation (labor charges) of the product. Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured.
This warranty gives you specific legal rights and you may also have other rights that vary from state-to-state. Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties, expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims the implied warranty of merchantability. (Dated proof of purchase required.)
Air Lift 1000 ........................Lifetime Limited
RideControl ........................Lifetime Limited
LoadLifter 5000*.................Lifetime Limited
LoadLifter 5000 Ultimate ...Lifetime Limited
SlamAir ...............................Lifetime Limited
AirCell .................................Lifetime Limited
Air Lift Performance** ..........1 Year Limited
LoadController/Single ..........2 Year Limited
LoadController/Dual .............2 Year Limited
Load Controller (I) ................2 Year Limited
Load Controller (II) ...............2 Year Limited
SmartAir ................................2 Year Limited
Wireless AIR..........................2 Year Limited
WirelessONE .........................2 Year Limited
Other Accessories ................2 Year Limited
*formerly SuperDuty
**formerly LifeSTYLE & Performance, EasyStreet
16
MN-850
LoadLifter 5000 Ultimate
Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at
(800) 248-0892. Most parts are immediately available and can be shipped the same day.
Contact Air Lift Company customer service at (800) 248-0892, first if:
• Parts are missing from the kit.
• Need technical assistance on installation or operation.
• Broken or defective parts in the kit.
• Wrong parts in the kit.
• Have a warranty claim or question.
Contact the retailer where the kit was purchased:
• If it is necessary to return or exchange the kit for any reason.
• If there is a problem with shipping if shipped from the retailer.
• If there is a problem with the price.
Contact Information
If you have any questions, comments or need technical assistance, contact our customer service department by calling (800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our local number is (517) 322-2144.
For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is 2727 Snow Road, Lansing, MI 48917.
You may also contact us anytime by e-mail at [email protected] or on the web at www.airliftcompany.com.
MN-850
17
Need Help?
Contact our customer service department by calling
(800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our local number is (517) 322-2144.
Register your warranty online at www.airliftcompany.com/warranty
Thank you for purchasing Air Lift products — the professional installer’s choice!
Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftcompany.com
Printed in the USA
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Key Features
- Durable construction
- Load leveling support
- Air adjustability
- Internal jounce bumper
- Safe operation at zero air pressure
Frequently Answers and Questions
Will installing air springs increase the weight ratings of a vehicle?
Is it necessary to keep air in the air springs at all times and how much pressure will they need?
Is it necessary to add a compressor system to the air springs?
Related manuals
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Table of contents
- 4 Introduction
- 4 Important Safety Notice
- 4 Notation Explanation
- 5 Installation Diagram
- 6 Hardware and Tools Lists
- 7 Installing the LoadLifter 5000 Ultimate System
- 7 Getting Started
- 8 Raising the Vehicle
- 8 Assembling the Air Spring Unit
- 8 Attaching the Air Spring Assembly
- 10 Checking the Air Spring Alignment
- 11 Checking for Leaks
- 12 Fixing Leaks
- 13 Before Operating
- 13 Installation Checklist
- 13 Post-Installation Checklist
- 14 Product Use, Maintenance and Servicing
- 14 Minimum Recommended Pressure and Maximum Pressure
- 14 Maintenance Guidelines
- 14 Troubleshooting Guide
- 15 Frequently Asked Questions
- 15 Tuning the Air Pressure
- 16 Guidelines for Adding Air
- 17 Choosing the Right On-Board Air Compressor System
- 18 Warranty and Returns Policy
- 19 Replacement Information
- 19 Contact Information