Transcript
MTE Tru-Ride Air Suspension Owner’s Manual GM 4500/5500
• Operation • Maintenance • Troubleshooting • Service Parts
MONROE TRUCK EQUIPMENT 1051 W. 7th Street • Monroe, WI 53566 800-356-8134 • www.monroetruck.com
05090311
NHTSA Notification If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHSTA) in addition to notifying Monroe Truck Equipment. If NHTSA receives similar complaints, it may open an investigation, and if it finds a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Monroe Truck Equipment. To contact NHTSA, you may either call the Auto Safety Hotline toll-free 1-800-424-9393 (or 366-0123) in Washington, DC area) or write to: NHTSA, U.S. Department of Transportation, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.
Notice Specifications, parts descriptions, illustrations, and instructions in this manual were accurate at the time of publication. Monroe Truck Equipment, Inc. reserves the right to discontinue products and to change specifications and designs at any time without notice and without incurring obligation. Monroe Truck Equipment, Inc. is not responsible or liable for injury, damage, or loss caused by improper installation by the end user, misuse of the equipment, lack of maintenance, accidents, or failure to follow instructions. In cases where equipment application was determined by the end user, Monroe Truck Equipment, Inc. is not responsible or liable for injury, damage, or loss caused by misapplication of this equipment
MTE Air Suspension Owner’s Manual Revision Level July 28, 2008 Copyright © 2007 Monroe Truck Equipment, Inc. 1051 W. 7th Street Monroe, WI 53566 No part of this manual may be used, reproduced, or reprinted without the express written permission of Monroe Truck Equipment, Inc.
Table of Contents Safety Warnings and Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Product Description & Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Routine Maintenance & Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service Parts 4X2, 11K & 13.5K Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 4X4, 13.5K Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-27 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-35 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37
1
Warnings & Safety Statements Danger of electrical shock. High current potential at compressor power connection.
WARNING
Disconnect the vehicle battery or remove the primary power fuse before removing the compressor enclosure cover.
Danger of injury from release of compressed air. The compressed air system normally operates at 120 psig. Sudden release of air pressure can cause eye injuries and loss of
WARNING
sight. Wear eye protection when working on the air system components. Disconnect power from the compressor and release all air pressure before working on the air system. Possible wiring damage or vehicle fire from improper fusing. Do not bypass the supplied fuses in the electrical circuits. Do not install fuses with a higher current rating than those
CAUTION
supplied. If a fuse burns out, investigate and repair the cause.
The air suspension system is not considered to be user-serviceable. It is recommended that service and repairs be performed by a Monroe Truck Equipment facility or other truck equip-
NOTE
ment repair shop.
2
Product Description & Specifications Product Description The MTE air suspension system replaces the OEM leaf spring suspension with swing arms and air springs (inflatable air bags). An airspring system provides a smoother ride and is self-leveling during all driving and normal loading conditions. Adjustable-dampening shock absorbers are standard with all suspension kits. A rear sway bar is standard. The air suspension system requires an MTE air compressor unit and air reservoir. Operating Parameters and Specifications
x
Required operating voltage (air compressor): +11 to 15 VDC
x
Operating air pressure (compressor shut-off) setpoint: 120 psig, + 5 psig
x
Operating temperature range: -40 to 130o F
Shock Absorber Settings Softest Setting
R
Standard MTE Setting
F
High Center of Gravity Vehicles (Ambulances & Buses)
XF
To adjust settings, follow directions on the shocks.
Ride Height (Measurement “H” shown at right) 4 x 2 wheel drive
11.125”
4 x 4 wheel drive
12.0”
So-Low 4 x 2 wheel drive
8.625”
H
The air suspension system is a loadleveling system designed to maintain a specified ride height. The specified ride height sets the inflatable air bags at their mid-point of travel
CAUTION
when the suspension is at rest. Operation of the vehicle with the ride height set too high or too low may permanently damage the air bags.
3
Normal Operation Normal Operation of the Air System
y For normal operation, keep the Dump (Kneel) switch off. y Start the vehicle engine.
If the air pressure in the system is low, the compressor will start immediately. When the
pressure reaches the normal operating pressure, the compressor will stop automatically.
y Normal maximum operating pressure is 120 psig.
The compressor will start whenever the pressure drops to about
100 psig.
y Whenever the vehicle is running, you will hear the compressor start and stop occasionally.
The frequency of com-
pressor cycling depends on the amount of movement at the rear suspension. As the suspension moves, it consumes and releases air pressure to keep the chassis level. The more the suspension moves up and down, the more frequently the compressor will have to run.
y To lower the rear of the vehicle when connecting a trailer, activate the Dump (Kneel) switch.
The suspension will
immediately deflate. When the trailer is connected, shut off the Dump switch and verify that the suspension returns to the normal ride height. Never drive the vehicle with the suspension in the Kneel position.
y It is normal for the compressor to start when the Dump function is shut off and the suspension begins to inflate.
Dump/Kneel Switch
4
Emergency Operation System Operation During Compressor Failure If the compressor or other component in the enclosure fails and the compressor will not run, air pressure can still be maintained in the suspension system until repairs can be made. Use a compressed air source and a standard tire valve chuck to add air at the Schrader valve in the end of the air tank.
y Do not exceed 120 psig when adding air to the tank manually. y If the vehicle must be operated for an extended period in the failure mode, air will have to be added occasionally to compensate for losses due to movement of the suspension.
y If there is an air leak in the system, manual filling of the tank may not be effective except for moving the vehicle a short distance.
y Do not use the Dump (Kneel) function if the system is operating in the failure mode.
Manual air fill valve
Never drive the vehicle with the air bags deflated. Permanent damage to the air bags may occur. If the compressor system fails, add air manually to the air tank to allow the vehi-
CAUTION
cle to be moved to a repair location. Repair the cause of the compressor system failure as soon as possible.
5
Routine Maintenance The vehicle owner is responsible for inspection after first 1,000 miles of operation, periodic inspections, maintenance, and proper use of the system. Suspension components must be inspected and all fasteners and U-bolts retightened after the first 1,000
CAUTION
miles of operation. Failure to retighten all suspension fasteners at 1,000 miles may result in damage to suspension components or the axle.
Refer to the Air Compressor Owner’s manual for maintenance information on the air system.
NOTE
Frequency Task Blow down moisture in air tank 1, 2
Weekly
Monthly
Annually
Other
X
Activate Dump (Kneel) function
X
Observe/check ride height
X
Inspect wiring harnesses & air tubing
X
Inspect shock absorbers
X
Inspect suspension components and bushings
X
Inspect condition of air bags
X
Tighten suspension component fasteners
X
Replace at 50,000 miles. Initial inspection after first 1,000 miles.
Initial check after first 1,000 miles. Tighten every 25,000
Notes 1.
Pull cable attached to drain valve at bottom of tank.
2.
If the air tank is equipped with the optional automatic drain valve, the valve should open briefly each time the compressor runs.
6
Routine Maintenance
FASTENER TORQUE VALUES Spring Hanger to Frame:
80 ft-lbs
Air Spring Bracket to Frame:
80 ft-lbs
Lateral Control Rod Bracket to Frame:
80 ft-lbs
Lateral Control Rod Bracket to Axle (U-Bolts)
150 ft-lbs
Lateral Control Rod Flange Nuts
140 ft-lbs
Air Spring mount to Spring Arm
30 ft-lbs
Spring Arm Axle Mount (U-Bolts)
275 ft-lbs
Spring Arm Front Mount Pivot
240 ft-lbs
Shock Absorber Nuts
60 ft-lbs
Repairs yMajor repairs and suspension component replacement should be performed by a qualified service technician.
7
Troubleshooting—Suspension Refer to the Air Compressor Owner’s manual for information on troubleshooting air system problems.
NOTE
Problem
Possible Causes
Solutions
Air bags do not inflate—bags deflated
1.
Dump (kneel) switch on.
1.
Turn Dump function off.
2.
Compressor unit failure.
2.
3.
Large air leak in system.
Refer to troubleshooting instructions for air compressor.
4.
Leveling valve link rod(s) disconnected.
3.
Check for and repair leaks.
4.
Reconnect link rod(s), adjust ride height if required.
5.
Inspect all air hose routings, re-
5.
One air bag deflated
Pinched or kinked air hose between air tank and leveling valve(s)
1.
Air bag ruptured, leaking.
2.
Leveling valve for bag disconnected or defective.
3.
1. Check for air leaks at bag, replace if ruptured. 2. Check leveling valve link rod. Reconnect and adjust. Replace valve if defective.
Air hose to bag kinked or plugged.
3. Check air hose, repair or replace. Ride height low, high, or uneven from side to side
1.
Leveling valve(s) not adjusted properly.
1. Adjust link rod(s) as required to achieve proper height.
2.
Leveling valve arm or link rod
2. Repair or replace valve or link rod, then adjust for proper ride height.
bent. 3.
Defective leveling valve
3. Disconnect link rod and manually operate the arm. If air bag does not move through full range of travel, replace valve.
Suspension does not respond when weight is added or removed from chassis.
1.
Leveling valve link rod(s) disconnected.
1.
Reconnect link rod(s), adjust ride height if required.
2.
Leveling valve defective.
2.
Check and replace leveling valve.
Excessive vertical movement of body on suspension or wheel hop under hard braking
1.
Shock absorbers not set to correct firmness.
1. Set shocks to higher firmness setting.
2.
Shock absorbers worn out.
2. Replace shocks.
8
Troubleshooting—Suspension Problem
Possible Causes
Solutions
Noise or excessive lateral movement in suspension.
1.
Fasteners loose.
2.
Bushing worn.
1. Tighten all fasteners for suspension components. 2. Check all bushings and replace as necessary.
Rough ride
Soft, mushy ride, poor handling.
1.
Tires over-inflated.
1. Check and adjust tire pressures.
2.
Ride height set too low.
2. Adjust ride height.
3.
Ride height set too high.
3. Adjust ride height.
4.
Shock absorber settings too high.
4. Check and adjust shock absorber settings.
1.
Ride height set too low.
1.
Adjust ride height.
2.
Shock absorbers worn out.
2.
Replace shock absorbers.
3.
Worn out bushing in suspen-
3.
Inspect and replace bushings.
sion components.
9
Electrical Schematic
10
Air Schematic
11
12
Service Parts Tru-Ride Air Suspension 4X2 11K & 13.5K Rear Axle
13
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
TRURIDE AIR SUSPENSION, 4X2, 11K & 13.5K REAR AXLE Item
Qty
Part Number
1
1
00108395
Air System Assembly (Refer to Parts Manual #05090310 for parts & service)
2
2
00111427
Shock Assembly, Standard
3
1
00111983
Assembly Kit, Air Suspension (Refer to pages 15-17 for parts)
4
1
00114421
Mounting Kit, Suspension, Standard (Refer to page 18 for parts)
5
2
W01-358-9750
1
00111995
Mounting Kit, 11K AXLE ONLY (Refer to page 19 for parts)
1
00111490
Mounting Kit, 13.5K AXLE ONLY (Refer to page 20 for parts)
6
Description
Air Spring Assembly, Standard
14
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
00111983 Assembly, Kit, Air Suspension
4
5
7 2
1
6
3
Item
Qty
Part Number
Description
1
2
00108307
Spring Arm Assembly
2
4
00108340
U-Bolt, Half Round, 3⁄4-16, 3.063
3
1
00108349
Torque Arm Assembly
4
1
00108382
Hardware Kit, Air Suspension (Refer to page 16 for parts)
5
2
00111428
Linkage Assembly
6
1
00111444
Air Line Kit, 60-84” CA (Refer to page 17 for parts)
7
2
90555057
Valve Assembly, Leveling, Haldex
15
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
00108382 Hardware Kit, Air Suspension 3
7
10
1
11
4
2
8
9
12 6
3
3
7
7
Item
Qty
Part Number
Description
1
4
05010643
Bolt, 3⁄8-16 x 1”, G8, HHCS, Zinc (Upper Air Bag)
2
2
05017092
Bolt, 5⁄8-11 x 4”, G8, HFHS, BP (Torque Arm)
3
30
05017098
Bolt, 1⁄2-13 x 13⁄4”, G8, HFHS, BP (Air Bag & Spring Arm Mounting Brackets)
4
4
05017102
Bolt, 1⁄2-13 x 23⁄4”, G8, HFHS, BP (Lower Air Bag)
5
4
05017105
Bolt, 3⁄4-10 x 3”, G8, HFHS, BP (Spring Arm)
6
4
05021067
Nut, M6-1, CLS8.8, Nylon Lock, SS (Ride Height Linkage)
7
30
05021098
Nut, 1⁄2-13, GG HF, Top Lock ,Z&W
8
4
05021099
Nut, 5⁄8-11, GG HF, Top Lock, Z&W
9
4
05021100
Nut, 3⁄4-10, GG HF, Top Lock, Z&W
10
4
05021365
Washer, 3⁄8”, Lock, Zinc
11
4
05021005
Washer, 1⁄2”, Flat, Mil-Carb, SAE
12
2
14CCFA1
Nut, M14-2, G10 HF, Top Lock, Z&W (Sway Bar Linkage)00
16
5
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
00111444 Air Line Kit, 60-84” CA Item
Qty
Part Number
Description
1
1
00111422
Tube, Air, J844, TP-B, Black, 3⁄8” x 120” (Air System to Tank)
2
1
00111437
Tube, Air, J844, TP-A, Black, 1⁄4” x 72” (Air System to Tee)
3
1
00111438
Tube, Air, J844, TP-A, Green, 1⁄4” x 72” (Air System to Tee)
4
1
00111439
Tube, Air, J844, TP-A, Black, 1⁄4” x 36” (Tee to LH Leveling Valve)
5
1
00111440
Tube, Air, J844, TP-A, Green, 1⁄4” x 36” (Tee to LH Leveling Valve)
6
2
00111441
Tube, Air, J844, TP-A, Black, 1⁄4” x 30” (Leveling Valve to Air Bag)
7
1
00111442
Tube, Air, J844, TP-A, Black, 1⁄4” x 84” (Tee to RH Leveling Valve)
8
1
00111443
Tube, Air, J844, TP-A, Green, 1⁄4” x 84” (Tee to RH Leveling Valve)
Black air lines are air system supply. Green air lines are air system discharge.
17
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
00114421 Mounting Kit, Suspension, Standard 3
5
8 9 4 1
6 10
7
2 11
Item
Qty
Part Number
Description
1
1
00108319
Bracket Weldment, Mounting, Air Spring, RH
2
1
00108320
Bracket Weldment, Mounting, Air Spring, LH
3
2
00108321
Spacer, Frame, Spring Arm
4
2
00108334
Shim Plate, Spring Arm
5
1
00111430
Top Plate Weldment, Axle, RH
6
1
00111463
Bracket Weldment, Stabilizer, RH
7
1
00111468
Bracket Weldment, Stabilizer, LH
8
1
00114406
Bracket Weldment, Mounting, Spring Arm, RH
9
1
00114407
Bracket Weldment, Mounting, Spring Arm, LH
10
1
00114411
Bracket Weldment, Mounting, Frame, Torque Arm
11
2
00114415
Bracket Weldment, Mounting, Bump Stop
18
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
0011995 Mounting Kit, 11K REAR AXLE
3
2
1
Item
Qty
Part Number
Description
1
1
00111992
Bracket Weldment, Torque Arm, Axle
2
1
00111994
U-Bolt Assembly, Round, 5⁄8-18
3
1
9.9117
Bump Stop, Air Ride, Red
19
Tru-Ride Air Suspension, 4X2, 11K & 13.5K Rear Axle
00111490 Mounting Kit, 13.5K REAR AXLE
1
2
Item
Qty
Part Number
Description
1
1
00114420
Bracket Weldment, Mounting, Axle, Torque Arm
2
1
00111429
Top Plate Weldment, Axle, LH
20
Service Parts Tru-Ride Air Suspension 4X4 13.5K Rear Axle
21
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
TRURIDE AIR SUSPENSION, 4X4, 13.5K REAR AXLE Item
Qty
Part Number
Description
1
1
00108395
Air System Assembly (Refer to Parts Manual #05090310 for parts & service)
2
1
00111983
Assembly Kit, Air Suspension (Refer to pages 23-25 for parts)
3
1
00115534
Mounting Kit, Suspension, 4X4 (Refer to page 26 for parts)
4
2
00117392
Shock Assembly, 4X4
5
1
00117600
Hardware Kit, 4X4 (Refer to page 27 for parts)
6
2
W01-358-9750
Air Spring Assembly, Standard
22
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
00111983 Assembly, Kit, Air Suspension
4
5
7 2
1
6
3
Item
Qty
Part Number
Description
1
2
00108307
Spring Arm Assembly
2
4
00108340
U-Bolt, Half Round, 3⁄4-16, 3.063
3
1
00108349
Torque Arm Assembly
4
1
00108382
Hardware Kit, Air Suspension (Refer to page 24 for parts)
5
2
00111428
Linkage Assembly
6
1
00111444
Air Line Kit, 60-84” CA (Refer to page 25 for parts)
7
2
90555057
Valve Assembly, Leveling, Haldex
23
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
00108382 Hardware Kit, Air Suspension 3
7
10
1
11
4
2
8
9
12 6
3
3
7
7
Item
Qty
Part Number
Description
1
4
05010643
Bolt, 3⁄8-16 x 1”, G8, HHCS, Zinc (Upper Air Bag)
2
2
05017092
Bolt, 5⁄8-11 x 4”, G8, HFHS, BP (Torque Arm)
3
30
05017098
Bolt, 1⁄2-13 x 13⁄4”, G8, HFHS, BP (Air Bag & Spring Arm Mounting Brackets)
4
4
05017102
Bolt, 1⁄2-13 x 23⁄4”, G8, HFHS, BP (Lower Air Bag)
5
4
05017105
Bolt, 3⁄4-10 x 3”, G8, HFHS, BP (Spring Arm)
6
4
05021067
Nut, M6-1, CLS8.8, Nylon Lock, SS (Ride Height Linkage)
7
30
05021098
Nut, 1⁄2-13, GG HF, Top Lock ,Z&W
8
4
05021099
Nut, 5⁄8-11, GG HF, Top Lock, Z&W
9
4
05021100
Nut, 3⁄4-10, GG HF, Top Lock, Z&W
10
4
05021365
Washer, 3⁄8”, Lock, Zinc
11
4
05021005
Washer, 1⁄2”, Flat, Mil-Carb, SAE
12
2
14CCFA1
Nut, M14-2, G10 HF, Top Lock, Z&W (Sway Bar Linkage)
24
5
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
00111444 Air Line Kit, 60-84” CA Item
Qty
Part Number
Description
1
1
00111422
Tube, Air, J844, TP-B, Black, 3⁄8” x 120” (Air System to Tank)
2
1
00111437
Tube, Air, J844, TP-A, Black, 1⁄4” x 72” (Air System to Tee)
3
1
00111438
Tube, Air, J844, TP-A, Green, 1⁄4” x 72” (Air System to Tee)
4
1
00111439
Tube, Air, J844, TP-A, Black, 1⁄4” x 36” (Tee to LH Leveling Valve)
5
1
00111440
Tube, Air, J844, TP-A, Green, 1⁄4” x 36” (Tee to LH Leveling Valve)
6
2
00111441
Tube, Air, J844, TP-A, Black, 1⁄4” x 30” (Leveling Valve to Air Bag)
7
1
00111442
Tube, Air, J844, TP-A, Black, 1⁄4” x 84” (Tee to RH Leveling Valve)
8
1
00111443
Tube, Air, J844, TP-A, Green, 1⁄4” x 84” (Tee to RH Leveling Valve)
Black air lines are air system supply. Green air lines are air system discharge.
25
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
00115534 Mounting Kit, Suspension, 4X4 6 19
1
17
13 3
2
15 11 16 9
5 4
12 14
7
8 10 Item
Qty
Part Number
Description
1
2
00108321
Spacer, Frame, Spring Arm
2
2
00108334
Shim Plate, Spring Arm
3
1
00111463
Bracket Weldment, Stabilizer, RH
4
1
00111468
Bracket Weldment, Stabilizer, LH
5
1
00115535
Bracket Weldment, Spring Arm, LH
6
1
00115536
Bracket Weldment, Spring Arm, RH
7
2
00115574
Offset Plate Weldment, Air Spring
8
1
00115576
Bracket Weldment, Air Spring, LH
9
1
00115577
Bracket Weldment, Air Spring, RH
10
1
00115582
Bottom Plate Weldment, Spring Arm, LH
11
1
00115585
Top Plate Weldment, Axle, RH
12
1
00117364
Bracket Weldment, Mounting,, Torque Arm
13
1
00117380
Bracket Weldment, Frame ,Torque Arm
14
1
00117383
Bracket Weldment, Bump Stop, LH
15
1
00117384
Bracket Weldment, Bump Stop, RH
16
1
00117395
Bottom Plate Weldment, Spring Arm, RH
17
2
00117396
Spacer Weldment, Stabilizer
19
2
00119140
Bracket, Mounting, Brake Cable 26
Tru-Ride Air Suspension, 4X4, 13.5K Rear Axle
00117600 Hardware Kit, 4X4 3 2
1 5
6
4
Item
Qty
Part Number
Description
1
2
05010593
Bolt, 1⁄4-20 x 1”, G8, HHCS, Zinc (Brake Cable)
2
4
05014690
Bolt, 1⁄2-13 x 1”, FSHCS, BP (Air Bag Offset Mounting Plate)
3
8
05017098
Bolt, 1⁄2-13 x 13⁄4”, G8, HFHS BP (Sway Bar Brackets)
4
2
05020910
Nut, 1⁄4-20, G8, Nylon Lock, Zinc
5
12
05021098
Nut,1⁄2-13, GG HF, Top Lock, Z&W
6
1
00117391
U-Bolt, Square, 5⁄8-18, 43⁄4” x 71⁄2” (Torque Arm Bracket to Axle)
27
28
OPTIONAL EQUIPMENT Tru-Ride Air Suspension
29
OPTIONS - 4X2 APPLICATION ONLY On-Spot Tire Chains Item
Qty
Part Number
Description
1
1
04632A8
On-Spot Chain System (Refer to the On-Spot Chain Manual for parts and service)
2
1
00114441
Mounting Kit, Bracket, On-Spot (See below for parts)
3
1
00114447
Assembly Kit, On-Spot (Refer to page 31 for parts)
00114441 Mounting Kit, Bracket, On-Spot 2
1
Item
Qty
Part Number
Description
1
1
00114439
Bottom Plate Weldment, On-Spot, RH
2
1
00114440
Bottom Plate Weldment, On-Spot, LH
30
OPTIONS - 4X2 APPLICATION ONLY 00114447 Assembly Kit, On-Spot 5
6
REMOVE BUSHING & SCHRADER VALVE RE-INSTALL INTO STREET TEE
DETAIL A SCALE .5
4
6
10
1
2
7
3 A
AIR SUSPENSION TANK 9
Item
Qty
Part Number
1
1
00108387
2
1
3149-6
Plug, Countersunk, 3⁄8” MNPT
3
2
3220-6-4
Bushing, 3⁄8” MNPT, 1⁄4” FNPT
4
1
3327-06-2
Nipple. Long, 3⁄8” NPT x 2”
5
1
3750-6
6
2
AQ68-DOT6X6
7
1
HT-1047
Mounting Kit, Air Tank, 8” O.D.
8
1
KN21102
Drain Valve, 1⁄4” MNPT, 24” Cable
9
1
N1178AB
Relief Valve, 150 PSI, 3⁄8” NPT
10
1
PV2668C
Valve, Protection, Pressure
1
---
3
8
Description Air Tank, 8” O.D. x 24”
Tee, Street, 3⁄8” NPT Connector, 3⁄8” Air, 3⁄8” MNPT
Tube, Air, J844, TP-B, Black, 3⁄8” (Length dependent on additional air tank mounting location.)
31
150 PRESSURE RELIEF VALVE
AIR TANK
32
MANUAL DISCHARGE VALVE
SCHRADER VALVE
AIR SUSPENSION TANK
80
85
PRESSURE PROTECTION VALVE
CLOSED
OPEN
150 PRESSURE RELIEF VALVE
AIR TANK
ON-SPOT SOLENOID
NC
MANUAL DISCHARGE VALVE
ELBOW 1/4” NPT X 3/8” AIR
ONSPOT SWITCH - DASH
ON-SPOT AIR CYLINDER
ON-SPOT AIR CYLINDER
OPTIONS - 4X2 APPLICATION ONLY On-Spot Tire Chains, Air Schematic
OPTIONS - 4X2 & 4X4 APPLICATIONS 00114445 Ping Tank Assembly
9
10
5
2
7
12
6
11
3
1 4
13
8
Item
Qty
Part Number
1
2
00114443
Air Tank, 6” O.D. x 18”
2
4
00114444
Bracket, Mounting, Air Tank
3
4
3149-8
4
2
3220-8-4
Bushing, 1⁄2” MNPT, 1⁄4” FNPT
5
4
3325-8-8
Nipple, Hex, 1⁄2” NPT
6
2
3400-8
Elbow, 90˚, Street, 1⁄2” NPT
7
2
3700-8
Tee, Union, 1⁄2” NPT
8
2
501A-3-12-20
Air Valve, Ping Tank
9
2
AQ64-DOT-4
Tee, Union, 1⁄4” Air
10
2
AQ68-DOT-8X8
11
2
AQ69-DOTS-4X2
Elbow, 90˚, Swivel, 1⁄4” Air, 1⁄8” MNPT
12
2
AQ69-DOTS-8X8
Elbow, 90˚, Swivel, 1⁄2” Air, 1⁄2” MNPT
13
2
KN21102
2
---
2
---
5
Description
Plug, 1⁄2” NPT
Connector, 1⁄2” Air, 1⁄2” MNPT
Drain Valve, 1⁄4” MNPT, 24” Cable Tube, Air, J844, TP-A, Green, 1⁄4”, Tee (#9) to Air Valve (#8) (Length is dependent on air tank mounting location) Tube, Air, J844, TP-B, Black, 1⁄2”, Air Valve Elbow (#12) to Air Bag Tee (#7) (Length is dependent on air tank mounting location) 33
TO AIR SYSTEM
34 AIR SPRING
SUP
DEL 2
DEL 2
SUP
AIR SPRING
RIDE HEIGHT VALVE
RIDE HEIGHT VALVE
MANUAL DISCHARGE VALVE
AIR TANK
AIR TANK
MANUAL DISCHARGE VALVE
N.C.
N.C.
CYL
CYL
OPTIONS - 4X2 & 4X4 APPLICATIONS Ping Tank, Air Schematic
OPTIONS - 4X2 & 4X4 APPLICATIONS 00111436 Mounting Kit, Air Tank/Compressor 1
2
Used to mount air system assembly under LH rear steps of crew cab & air tank under RH rear steps of crew cab. Typical Application: VH Towing Bodies & Pickups Item
Qty
Part Number
Description
1
1
00111431
Mounting Plate, Air Tank
2
2
00110394
Bracket, Mounting, Compressor
00117367 Bracket Weldment, Inner, Air System Used to: • Mount air system assembly on inside of frame rails • Mount air tank & relocate air system Typical Application: Ambulance
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MTE Air Suspension Systems 3-Year Limited Warranty Monroe Truck Equipment (MTE) Limited Warranty Coverage x Structural fabricated components are warranted against defects and failure due to materials and workmanship for 3 years or 36,000 miles. x Powder-coat paint finish is warranted against cracking, checking, peeling, and delamination for 3 years or 36,000 miles. x Assembly and installation workmanship for MTE components is warranted for 3 years or 36,000 miles. x Purchased components (items not manufactured by MTE) are covered by the supplier’s warranty policy. Major components: o Firestone air springs are covered for 2 years or 200,000 miles, whichever comes first o Haldex leveling valves are covered for 1 year or 100,000 miles, whichever comes first. o ArvinMeritor shock absorbers are covered for 1 year or 100,000 miles, whichever comes first. o Thomas air compressors are covered for 1 year, regardless of mileage. Eligibility for Warranty Coverage x This warranty applies only to air suspension systems specified and installed by MTE or an authorized distributor. x The vehicle must be operated within the weight ratings for the axles (GAWR front and rear) and the overall chassis (GVWR). x Warranty period commences from the in-service date for the original owner. x Original owner must complete and submit the Warranty & Serial Number Registration Card within thirty (30) days of purchase. x The suspension components must be maintained and serviced according to the guidelines in the supplied owner’s manual. Exclusions x The 3-year limited warranty applies only to fabricated suspension components and excludes non-MTE components and accessories, which are covered by separate and specific warranties. x Any modifications or additions to the vehicle suspension that change the suspension height, suspension travel, or driveline angle may void the warranty. x Any use or application of the suspension system for off-road driving, racing, or other purpose not specified, intended, or foreseen by MTE will void the warranty. x Warranty does not apply to any product that has been transferred to another vehicle, altered, overloaded, abused, or misused. x Warranty does not apply to systems or components sold and used outside the United States and Canada. x Failure of any components resulting from or related to collisions or accidents is not covered. x Parts considered wear items and “consumables”, such as filters and light bulbs, are not covered by any part of this warranty. x This warranty is not transferable. Warranty Repairs Performed by MTE or Authorized Agents Warranty repairs shall be performed at an MTE facility or at an authorized distributor or dealer. MTE may, at its discretion, pick up and return the vehicle to the owner’s location or may request that the owner deliver the vehicle to the repair site. Warranty Repairs Performed by Non-MTE Entities MTE may authorize a third party to perform warranty repairs. Any such decision will be based on type of repair, distance to the nearest approved MTE repair site, and urgency of the repair. MTE must grant authorization and permission before a non-MTE entity begins repair or replacement of components. Warranty claims for unauthorized and unsubstantiated work may be denied. Peripheral, Incidental, and Consequential Damages and Claims The MTE limited warranty does not apply to damage and failure resulting from misuse, abuse, neglect, accident, improper customer/distributor installation, lack of maintenance, or acts of God. Any modifications by the buyer or any third party, without the prior written consent of MTE, may void this warranty. Operating conditions, or applications not made known to or contemplated by MTE at the time of delivery to the buyer may also void this warranty. Damages resulting from any other abnormal operation will not be covered by this warranty. Normal maintenance, wear, and consumable items are not covered under this warranty. MTE will not reimburse for lost time, business, or business opportunity, or for any loss of use related to warranty claims. MTE will not provide or pay for the use of a rental vehicle, equipment, or tools while warranty work is performed. MTE will not reimburse for equipment or tools that are damaged, lost, or missing in conjunction with a warranty claim. MTE is not responsible for and will not reimburse for mileage, fuel, and wear incurred in the process of driving the vehicle to a repair site or delivery to the end user location, nor for lost time incurred by an owner delivering and picking up a vehicle. This limited warranty is the sole and exclusive remedy for defective products manufactured and/or installed by MTE.
36
MTE Air Suspension Systems 3-Year Limited Warranty How to Obtain Warranty Service from Monroe Truck Equipment Making an Appointment for Warranty Service at an MTE Facility or Authorized Repair Site
1. Obtain the following information:
x
Vehicle Identification Number (VIN)
x
Type, model, and serial number of component or product requiring service
x
Number of original MTE Sales Order if available
x
Name of dealer that vehicle was purchased from if known
x
Date of purchase/in-service date if known
x
Detailed description of the problem
2. Call the MTE location where your truck was built. The build location will be marked on the yellow certification label in or near the driver’s door jamb.
x
Monroe, Wisconsin: 1-608-329-8437 (Warranty Dept.) or 1-800-356-8134 (ask for Warranty Dept.)
x
Flint, Michigan: 1-877-233-2030 (ask for Warranty Dept.)
x
De Pere, Wisconsin: 1-800-848-5400 (ask for Service Dept.)
x
Marshfield, Wisconsin: 1-800-882-1900 (ask for Service Dept.)
x
Joliet, Illinois: 1-800-892-7052 (ask for Service Dept.)
3. Discuss the problem with the Warranty representative to determine resolution and repair schedule. Please let the Warranty representative know if your vehicle was sold with an extended or other non-standard warranty policy! Requesting Authorization to Perform Warranty Work or Payment for Work Performed
1. Obtain the following information:
x
All of the information requested in item #1 above, plus:
x
Documented photographs for any physical damage. (paint, dents, etc.)
x
Inspection notes by MTE personnel or a third party representing MTE if necessary.
2. Call the MTE location where your truck was built. The build location will be marked on the yellow certification label in or near the driver’s door jamb. See the location list in item #2 above.
3. Discuss the problem with the Warranty representative to determine coverage and repair method. 4. The representative will grant permission to perform repairs if approved. 5. The representative will issue a Returned Goods Authorization (RGA) number. 6. Defective parts must be returned freight prepaid to MTE within ten days. 7. If the affected component was purchased from a non-MTE supplier, please allow extra time for MTE to contact and work with the supplier. Monroe Truck Equipment reserves the right to deny any warranty if the procedures detailed above are not followed. Proper documentation, including photos, must be provided in order for MTE to validate and approve any claim submitted after repairs are done.
Policy revision/effective date: 06/09/08
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