MTE Tru-Ride Air Suspension Owner’s Manual Ram 4500/5500€¦ · The specified ride height sets...

MONROE TRUCK EQUIPMENT1051 W. 7th Street • Monroe, WI 53566800-356-8134 • www.monroetruck.com 05090506

06/15/12

MTE Tru-Ride Air SuspensionOwner’s ManualRam 4500/5500

• Operation

• Maintenance

• Troubleshooting

• Service Parts

MTE Air Suspension Owner’s Manual

Ford F450/550 Super Duty

Manual # 05090506

Revision Level June 15, 2012 Copyright © 2009

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 per-mission of Monroe Truck Equipment, Inc.

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 prod-ucts 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

std_disclaim.doc

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 Mon-roe 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 Wash-ington, 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.

1

Table of Contents

Safety Warnings and Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Product Description & Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Adjusting Ride Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18

Adjusting Quick-Recovery Valves . . . . . . . . . . . . . . . . . . . . . . . . . 19-26

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-51

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-53

2

Warnings & Safety Statements

WARNING

Danger of electrical shock. High cur-rent potential at compressor power connection.

Disconnect the vehicle battery or re-move the primary power fuse before removing the compressor enclosure cover.

WARNING

Danger of injury from release of com-pressed air.

The compressed air system normally operates at 120 psig. Sudden release of air pressure can cause eye injuries and loss of sight.

Wear eye protection when working on the air system components. Discon-nect power from the compressor and release all air pressure before work-ing on the air system.

CAUTION

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 supplied.

If a fuse burns out, investigate and repair the cause.

CAUTION

Possible damage to air springs from over-extension.

The full weight of the axle must not be allowed to pull on extended air springs. The flexible bellows may pull out of the crimped end plates, permanently damaging the springs.

If the shock absorbers are discon-nected, the rear axle must be sup-ported on stands while the vehicle is raised.

3

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 air-spring 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.

The air suspension system requires an MTE air compressor unit and air reservoir.

Operating Parameters and Specifications

Required operating voltage (air compressor): +11 to 15 VDC

Operating air pressure (compressor shut-off) setpoint: 120 psig, + 5 psig

Operating temperature range: -40 to 130o F

CAUTION

The air suspension system is a load-leveling system designed to maintain a specified ride height.

The specified ride height sets the in-flatable air bags at their mid-point of travel when the suspension is at rest.

Over or under-inflation of the air bags will result in rough ride and poor han-dling, and may permanently damage the bags.

Shock Absorber Settings

Standard 4 x 2 application 2

Ambulance, bus application 3 H

Ride Height (Dim. “H”)

Standard 4 x 2 wheel drive 7.0”

4

Normal Operation

Normal Operation of the Air System

For normal operation, keep the Dump (Kneel) switch off.

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.

Normal maximum operating pressure is 120 psig. The compressor will start whenever the pressure drops to about 100 psig.

The red “low-pressure” light will turn on if the system pressure drops below 60 psig. If the vehicle has not been started for several weeks, the low-pressure light may turn on briefly when the engine is started.

Whenever the vehicle is running, you will hear the compressor start and stop occasionally. The frequency of compressor 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.

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 suspen-sion returns to the normal ride height. Never drive the vehicle with the suspension in the Kneel position.

It is normal for the compressor to start when the Dump function is shut off and the suspension begins to in-flate.

Operation of Optional Quick-Recovery System

Your vehicle may be equipped with the optional “Quick-Recovery” system for rapid return to normal ride height from the “dump” (kneel) position.

Prior to placing the vehicle in service, verify that the Quick-Recovery air valves have been adjusted. These valves can only be adjusted after a body and all permanently attached equipment have been installed on the chassis. MTE does not adjust these valves when installing an air suspension on a bare chassis.

Following adjustment of the air valves, operation of the Quick-Recovery system is fully automatic.

When the air pressure has been “dumped” from the system and the “Dump” function is turned off, the sus-pension should return to its normal ride height in 1-2 seconds.

If the suspension takes longer than 2 seconds to rise from the dump (kneel) position to the normal ride height, the air valves need to be adjusted. Refer to the instructions in this manual.

NOTE

On ambulance applications where the “dump” function is controlled by switches at the rear doors, the ambu-lance body installer is responsible for all controls and wiring.

MTE is typically not involved in the installation or wiring of ambulance bodies.

First 1,000 Miles of Operation

Re-torque all fasteners, inspect all moving parts and bushings.

Check condition and routing of air tubing and wiring. Look for rubbing and wearing.

5

Emergency Operation System Operation During Compressor Failure

If the compressor or other component in the enclosure fails and the compressor will not run, air pres-sure 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.

Do not exceed 120 psig when adding air to the tank manually. Use a truck tire gauge to check the air pressure in the system.

If the vehicle must be operated for an extended period in the failure mode, air will have to be add-ed occasionally to compensate for losses due to movement of the suspension.

If there is an air leak in the system, manual filling of the tank may not be effective except for mov-ing the vehicle a short distance.

Do not use the Dump (Kneel) function if the system is operating in the failure mode.

CAUTION

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 vehicle to be moved to a repair location.

Repair the cause of the compressor system failure as soon as possible.

Manual air fill valve

6

Routine Maintenance

Notes

1. Pull cable attached to drain valve at bottom of tank.

2. The automatic tank drain valve will open briefly each time the compressor runs. The tank should be blown down manually every week to verify that the automatic valve is working.

Task Frequency

Weekly Monthly Annually Other

Blow down moisture in air tank 1, 2 X

Activate Dump (Kneel) function X

Observe/check ride height X

Inspect wiring harnesses & air tubing X Initial inspection af-ter first 1,000 miles.

Inspect shock absorbers X Replace at 50,000

miles.

Inspect suspension components and bushings

X Initial inspection af-ter first 1,000 miles.

Inspect condition of air bags X

Tighten suspension component fasten-ers

X

Initial check after first 1,000 miles.

Tighten every 25,000 miles or annually.

CAUTION

The vehicle owner is responsible for inspection after first 1,000 miles of operation, periodic in-spections, maintenance, and proper use of the system.

Suspension components must be inspected and all fasteners retightened after the first 1,000 miles of operation.

Failure to retighten all suspension fasteners at 1,000 miles may result in damage to suspension components or the axle.

NOTE Refer to the Air Compressor Owner’s manual

for maintenance information on the air com-pressor system.

7

Routine Maintenance—Dodge

Fastener Application Description Torque, ft/lbs. Comments

Zinc plated (yellow)

Cad plated (silver)

Air bag, bottom bolt 1/2-13 hex-head and flat socket

head bolts 25 n/a Non-standard torque value. Over-tightening may damage air bag.

Air bag, top studs 1/2-13 nut, flanged top-lock 30 n/a Non-standard torque value. Over-tightening may damage air bag.

Frame bracket mounting bolts, all 3/8" dia.

3/8-16 hex head bolt, black phos-phate w/flanged top-lock nut 37 27

Frame bracket mounting bolts, all 1/2" dia.

1/2-13 hex head bolt, black phos-phate w/flanged top-lock nut 80 70

Lower air spring plate brace 1/2-13 hex head bolt, black phos-

phate w/flanged top-lock nut 80 70

Frame bracket mounting bolts 5/8-11 hex head bolt, black phos-


Torque arm axle bracket 5/8-11 hex head bolt, black phos-


Spring arm axle clamp bolts 3/4-10 bolt, zinc, w/flanged top-lock

nut 280 200 Cad-plated nuts supplied and rec-ommended. Tighten evenly and progressively in torque increments.

Spring arm eye bolts 3/4-10 bolt, zinc, w/flanged top-lock

nut 280 200

Torque arm eye bolts 7/8-9 hex head bolt, zinc, w/cadmium/waxed, top-lock nut n/a 270 Use only cad-plated nut.

Shock absorber, top mounting nut

7/16-14 cadmium/waxed, top-lock nut n/a 37

Cad-plated nut supplied and rec-ommended.

Shock absorber, bottom mount-ing bolt

12-1.75 mm hex head bolt w/top-lock nut n/a 45

Fastener Tightening

Most top-lock nuts originally provided by MTE are cadmium-plated and high-pressure waxed to reduce friction and prevent galling during tightening. Be sure to use the correct tightening torque for cadmium-plated fasten-ers.

If zinc-plated fasteners are substituted during service repairs, be sure to use the correct torque values when tightening.

Note that cadmium plating is a silver color and zinc plating is a yellow/straw color.

8

NOTE

If fasteners are replaced, use only the same size, grade, and type of fastener originally supplied.

All fasteners must be tightened and checked with a tested and calibrated torque wrench.

NOTE

Torque values given here are based on the standard fasteners supplied with the original installation kit:

Grade 8

Flanged bolts and nuts for frame-mounted brackets.

Steel top-lock nuts and hardened flat washers

Most nuts supplied originally are cadmium-plated and waxed

Any changes to fastener specifica-tions will also change required tight-ening torque.

Fastener Tightening

Routine Maintenance—Dodge

9

Repairs

NOTE

The air suspension system is not con-sidered to be user-serviceable.

It is recommended that service and repairs be performed by a Monroe Truck Equipment facility or other truck equipment repair shop.

The air suspension system is not considered user-serviceable. Adjustment to the ride height of the vehicle should be made only by a qualified service technician. Improper

ride height can damage the suspension air bags. For repairs, contact a Monroe Truck Equipment facility or a truck repair shop. Maintenance and repairs to suspension parts should only be performed by a competent truck or suspension

shop. Replacement parts are available through Monroe Truck Equipment. See the parts lists on the following pages.

CAUTION

Possible damage to air springs from over-extension.

The full weight of the axle must not be allowed to pull on extended air springs. The flexible bellows may pull out of the crimped end plates, permanently damaging the springs.

If the shock absorbers are discon-nected, the rear axle must be sup-ported on stands while the vehicle is raised.

10

Troubleshooting—Suspension

Problem Possible Causes

Air bags do not inflate—bags deflated

1. Dump (kneel) switch on. 2. Compressor unit failure. 3. Large air leak in system. 4. Leveling valve link rod(s)

disconnected. 5. Pinched or kinked air hose

between air tank and lev-eling valve(s)

One air bag deflated 1. Air bag ruptured, leaking. 2. Leveling valve for bag dis-

connected or defective. 3. Air hose to bag kinked or

plugged.

Ride height low, high, or une-ven from side to side

1. Leveling valve(s) not ad-justed properly.

2. Leveling valve arm or link rod bent.

3. Defective leveling valve. 4. Suspension component

bent or damaged.

Suspension does not respond when weight is added or re-moved from chassis.

1. Leveling valve link rod(s) disconnected.

2. Leveling valve defective.

Excessive vertical movement of body on suspension or wheel hop under hard braking

1. Shock absorbers not set to correct firmness.

2. Shock absorbers worn out.

Solutions

1. Turn Dump function off. 2. Refer to troubleshooting

instructions for air compres-sor.

3. Check for and repair leaks. 4. Reconnect link rod(s), ad-

just ride height if required. 5. Inspect all air hose routings,

repair any kinks or block-ages.

1. Check for air leaks at bag, replace if ruptured.

2. Check leveling valve link rod. Reconnect and adjust. Re-place valve if defective.

3. Check air hose, repair or re-place.

1. Adjust link rod(s) as required to achieve proper height.

2. Repair or replace valve or link rod, then adjust for prop-er ride height.

3. Disconnect link rod and manually operate the arm. If air bag does not move through full range of travel, replace valve.

4. Inspect for damage affecting leveling valve operation.

1. Reconnect link rod(s), ad-just ride height if required.

2. Check and replace leveling valve.

1. Set shocks to higher firm-ness setting.

2. Replace shocks.

NOTE Refer to the Air Compressor Owner’s manual

for information on troubleshooting air compres-sor system problems.

11

Troubleshooting—Suspension Problem Possible Causes

Rough ride 1. Tires over-inflated. 2. Ride height set too low. 3. Ride height set too high. 4. Shock absorber settings

too high.

Soft, mushy ride, poor han-dling.

1. Ride height set too low. 2. Shock absorbers worn

out. 3. Worn out bushing in sus-

pension components.

Noise or excessive lateral movement in suspension.

1. Fasteners loose. 2. Bushing worn.

Optional Quick-Recovery does not work or is too slow

1. Air valves not adjusted properly.

2. Defective air valve(s). 3. Air leak in system.

Solutions

1. Tighten all fasteners for sus-pension components.

2. Check all bushings and re-place as necessary.

1. Adjust ride height. 2. Replace shock absorbers. 3. Inspect and replace bush-

ings.

1. Check and adjust tire pres-sures.

2. Adjust ride height. 3. Adjust ride height. 4. Check and adjust shock ab-

sorber settings.

1. Adjust air valves per instruc-tions.

2. If valve adjustment does not work, replace valve(s).

3. Check all air circuits for leaks.

12

Electrical Schematic

13

Air Schematic

14

Adjusting Ride Height

CAUTION

Suspension components can be dam-aged by over or under-inflation of the air bags.

The air suspension is an automatic leveling system with a specified ride height. The purpose of the system is to automatically maintain the speci-fied ride height regardless of load weight.

The specified ride height sets the in-flatable air bags at their mid-point of travel when the suspension is at rest.

Do not use the leveling valves to change the body height or angle for appearance or other purposes.

Over or under-inflation of the air bags will result in rough ride and poor han-dling, and may permanently damage the bags.

Look Action Task

15

4. Verify that the air bags are fully inflated and the compressor pump has stopped.

1. With the system pressurized and the air bags inflated, drive the vehicle a short distance around the parking lot to “settle” the suspension.

2. Park the vehicle in a level location.

3. Check and adjust the tire pressures.

CAUTION

Do not drive the vehicle with the air bags deflated, except to move it a short distance.

Driving with the air bags deflated can damage the internal bump stops.

Make sure there is enough air in the bags to raise the chassis a few inch-es.

Adjusting Ride Height (Cont’d)

16

Look Action Task

6. Measure the distance between the under-side of the frame and the tops of the air bag base plates. Measure and record the dimension on both sides.

7. Compare dimension to the table below.

Ride Height (Dim. “H”)

Standard 4 x 2 wheel drive 7.0”

8. If the ride height requires adjustment, loosen both lock nuts at the adjuster rod.

H

5. Verify that the system air pressure is 120 psig with the compressor off. Check the system pressure at the prima-ry tank emergency fill using a truck tire gauge.


Look Action Task

17

9. Remove the nut that fastens the upper rod pivot to the leveling valve arm and pull the stud out of the arm.

10. Turn the threaded rod an equal amount at each rod pivot. Both ends of the threaded rod are right-hand thread.

NOTE

For systems with dual leveling valves, the valves must be adjusted individu-ally for each side.

After initially setting both valves, check the ride height again and make minor adjustments as necessary.

NOTE When adjusting the length of the lev-eling rod, make equal changes at each end of the rod.

The thread at both ends of the rod is right-hand. One end of the rod must be disconnected in order to adjust the length.

Total available thread makeup at each end is about 5/8”. Maintain a mini-mum 1/4” thread makeup in the plas-tic ends.

If the ride height can not be adjusted with the available range of adjustment at the rod, check for a bent mounting at the leveling valve or other physical damage.

Keep thread engagement equal at each end


18

Look Action Task

11. Reinstall the top pivot stud in the valve arm and check the ride height. Re-adjust as necessary.

12. When the ride height is correct, tighten the nut on the pivot stud and tighten the lock nuts on the adjuster rod.

13. Cycle the air suspension up and down several times with the “dump” function. Recheck the ride height to verify that the system is functioning properly.


19

Adjusting Quick-Recovery Air Valves

20

Adjusting Quick-Recovery Air Valves

NOTE

The “Quick-Recovery” system is an optional feature that may not be in-stalled on your vehicle.

The Quick-Recovery system returns the vehicle to the normal ride height rapidly after the “Dump” function is used. This option is typically used on ambulances.

If desired, the Quick-Recovery system can be retrofitted to any MTE air sus-pension system. Contact MTE Sales for more information.

21

Look Action Task

Adjusting Quick-Recovery Air Valves (Cont’d)

5. Verify that the air bags are fully inflated and the compressor pump has stopped.

6. Verify that the system air pressure is 120 psig with the compressor off.

1. Park the vehicle in a level location.

2. Remove any heavy cargo from the body to avoid off-center loading.

3. Check and adjust the tire pressures.

4. Check the normal ride height of the air suspension and adjust the leveling valves if necessary.

NOTE

A body and all other permanently-installed equipment must be installed before the Quick-Recovery valves are adjusted. The full weight of the com-pleted installation must be on the rear suspension for proper valve adjust-ment.

Do not attempt to adjust the Quick-Recovery valves on an unfinished cab chassis.

Look Action Task

22

8. Activate the “Dump” function.

9. Verify that the air bags deflate and the chassis settles all the way down on the bump stops.

7. Loosen the lock nuts on the valve ad-juster bolts and turn the bolts nearly all the way out.

Loosen


23

Look Action Task

10. Measure and record the distance from the top of the swing arm to the bottom of the upper air bag bracket at the rear of the swing arm.

Bumps stops are inside the air springs on a Ford SD installation.

11. Shut off the “Dump” function and allow the air bags to fill and the vehicle to reach the normal ride height.


Look Action Task

24

NOTE

The purpose of the Quick Recovery system is to allow the suspension to drop to the “kneel” position without dumping all the air pressure. The re-sidual pressure in the system is what provides quick recovery to the normal ride height.

By measuring and adjusting the “kneel” height, it is not necessary to try to achieve a specific system air pressure in the “dump” mode.

13. Activate the “Dump” function again and allow the air bags to deflate.

14. Note in the photo that the air bags should not deflate fully when the Quick Recovery valves are active.

15. Measure and record the distance be-tween the swing arm and the upper bracket again.

16. If the chassis height dimension is 1/4” to 1/2” more than the originally measured dimension, the recovery valves are ad-justed properly.

12. Turn both Quick Recovery valve adjust-er bolts about 1/3 of the way in. Leave the lock nuts loose at this time.


25

Look Action Task

17. Note that for an ambulance application, the inside floor height must not be over 33” in the “dump” mode. The Quick Recovery valves can be adjusted to achieve this height requirement.

18. Adjust the Quick Recovery valves as required to achieve the “kneel” height of 1/4” to 1/2” higher than the fully deflat-ed height.

19. If the suspension is too low, deactivate the “dump” mode and turn the adjuster bolts in 1-2 turns. Engage the “dump” mode again and recheck the dimension.

20. If the suspension is too high, turn the adjuster bolts out slowly while still in the “dump” mode to achieve the re-quired “kneel” height.

NOTE

If the “kneel” height is too high, the valve adjuster bolts can be turned out slowly to release air pressure while in the “dump” mode.

However, if the “kneel” height is too low, the “dump” mode must be deac-tivated and the suspension raised to the normal ride height before adjust-ing the valves. Once the air dump is complete, turning the adjuster bolts in will not add air to the system.

33”

Raise

Lower


Look Action Task

26

21. When the valves are adjusted properly, tighten the lock nuts.

22. Cycle the air suspension up and down several times with the “dump” function. Recheck the “kneel” height to verify that the system is functioning properly.

Tighten


2727

Service Parts

Ram 4500/5500Tru-Ride Air Suspension

28

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29

TRURIDE AIR SUSPENSION, RAM 4500/5500Item Qty Part Number Description

1 1 00132509 Mounting Kit, Air Suspension, Ram (Refer to pages 30-31 for parts)

2 1 00135545 Assembly Kit, Air Suspension, Ram (Refer to pages 32-36 for parts)

3 1 00129216 Air System Assembly, Ford/Ram (Refer to Parts Manual #05090448 for parts & service)

3

2

1

30

6

5

2

6

4

9

3

4

10

8

13

117

12

10

14

17

16

16

15

1

18

18

19

00132509 Mounting Kit, Suspension, Ram

31

00132509 MOUNTING KIT, SUSPENSION, RAM

Item Qty Part Number Description

1 1 00131514 Bracket Weldment, Spring Arm, RH

2 1 00131516 Bracket Weldment, Air Spring, LH

3 1 00131519 Mounting Plate Weldment, Air Spring, LH

4 2 00135535 Brace Weldment, Air Spring, Lower

5 1 00131536 Bracket Weldment, Air Spring, RH

6 2 00126597 Bracket, Mounting, Leveling Valve

7 1 00126560 Bottom Plate Weldment, LH

8 1 00126568 Bottom Plate Weldment, RH

9 1 00131520 Mounting Plate Weldment, Air Sprint, RH

10 2 00130391 Adapter Weldment, Spring Clamp

11 1 00131525 Cradle Weldment, Axle, Lower

12 1 00131526 Cradle Weldment, Axle, Upper

13 1 00131599 Bracket Weldment, Torque Arm, RH

14 2 00131507 Spacer, Stabilizer Bar

15 1 00135522 Bracket Weldment, Spring Arm, LH

16 8 00135538 Spacer, Bottom Plate

17 1 00135530 Bracket Weldment, Mounting, Air Tank

18 4 00136049 Spacer Plate, Air Spring, FR

19 2 00143289 Spacer, Bolt, Torque Arm

32

4

2

6

10

1

9

5

13

11 12

87

14

15

17

16

00135545 Assembly Kit, Air Suspension, Ram

33

00135545 ASSEMBLY KIT, AIR SUSPENSION, RAM


1 2 00108307 Spring Arm Assembly

2 2 00111428 Linkage Assembly

3 1 00135546 Air Line Kit, Air Suspension (Not shown, refer to page 36 for parts)

4 2 00125688 Valve Assembly, Leveling, Air Ride

5 2 00126591 Shock Assembly, F450/F550

6 1 00132569 Hardware Kit, Air Suspension, Ram (Refer to pages 34-35 for parts)

7 1 05090506 Manual, Air Suspension, Ram

8 1 05090448 Manual, Air Compressor, Ford/Ram

9 2 15640806 Mounting Block, Axle, 5˚, OEM

10 1 00127772 Torque Arm Assembly, 23.75

11 1 BR630 Label, Ford Air Ride

12 1 BR631 Label, Low Air Pressure

13 4 W01-358-5379 Air Spring Assembly, Ford

14 4 00131504 Adapter, Shock

15 2 00137587 Pin, Shock, Upper

16 2 0160886 Washer, .454 ID x 1.25 OD, G9, ZC

17 2 05020985 Nut, .438-14, GC, TopLock, C&W

34

5 22 19 TORQUE ARM MTG

1325

2x - SPRING ARM MTG

9 24

10 24

TORQUE ARM FRAME MTG BRACKET

2 18 27 2x - LEVELING VALVE MTG BRACKET

24

14252x - SPRING ARM AXLE MTG

33

11

2x - LOWER AIR SPRING MTG

1224

9 24

2x - LOWER AIR SPRING BRACE

11 24 AXLE CRADLE MTG BRACKETS

11626

15 24

9 24

823

RH AIR SPRING MTG BRACKET

9 24

8 23

4 17 21 SWAY BAR SPACER

72031LOWER SHOCK MOUNT

2x - SPRING ARM BRACKET31827

32

62830

32729AIR TANK MTG BRACKET

2x - UPPER AIR SPRING MTG

LH AIR SPRING MTG BRKT

00132569 Hardware Kit, Air Suspension, Ram

3535

00132569 HARDWARE KIT, AIR SUSPENSION, RAM


1 2 05010593 Bolt, 1⁄4-20 x 1”, G8, HHCS, ZC

2 4 05010618 Bolt, 5⁄16-18 x 1”, G8, HHCS, ZC

3 3 05010619 Bolt, 5⁄16-18 11⁄4”, HHCS, Zinc

4 4 05010649 Bolt, 3⁄8-16 x 21⁄2”, G8, HHCS, ZC

5 2 05017193 Bolt, 7⁄8-9 x 7”, G8, HHCS, ZC

6 2 05016993 Bolt, M10-1.5 x 40, G10.9, HHCS, ZC

7 2 05017001 Bolt, M12-1.75 x 85 G10.9, HHCS, ZC

8 6 05017094 Bolt, 3⁄8 -16 x 11⁄2”, G8, HFHS, BP

9 25 05017097 Bolt, 1⁄2 -13 x 11⁄2”, G8, HFHS, BP

10 4 05017098 Bolt, 1⁄2-13 x 13⁄4”, G8, HFHS, BP

11 8 05017100 Bolt, 1⁄2-13 x 21⁄4”, G8, HFHS, BP

12 4 05017102 Bolt, 1⁄2-13 x 2 3⁄4”, G8, HFHS, BP

13 4 05017105 Bolt, 3⁄4 -10 x 3”, G8, HFHS, BP

14 8 05017151 Bolt, 3⁄4 -10 x 13”, G8, HHCS, ZC

15 1 05017152 Bolt, 1⁄2-13 x 2”, FSHCS, BP

16 2 05020536 Nut, 1⁄4-20, G2, Nylon Lock, ZC

17 4 05020898 Nut, 3⁄8 -16, GC, Top Lock, C&W

18 5 05020909 Nut, 5⁄16-18, GC, Top Lock, C&W

19 2 05020969 Nut, 7⁄8-9, GC, Top Lock, C&W

20 4 05021005 Washer, 1⁄2”, Flat, Mil-Carb, SAE


22 4 05021019 Washer, 7⁄8”, Flat Mil-Carb, SAE

23 6 05021097 Nut, 3⁄8 -16, GG, HF, Top Lock, Z&W

24 48 05021098 Nut, 1⁄2-13, GG, HF, Top Lock, Z&W

25 12 05021100 Nut, 3⁄4 -10, GG, HF, Top Lock, Z&W

26 4 05021305 Washer, 1⁄4”, Flat, ZC

27 12 05021306 Washer, 5⁄16”, Flat, ZC

28 2 05021307 Washer, 3⁄8”, Flat, ZC

29 2 05021364 Washer, 5⁄16”, Lock, ZC

30 2 MLW5 Washer, M10, Lock, ZC

31 2 EHPC Nut, M12-1.75, GC, Toplock, ZC

32 2 ARS4-518-280 PlusNut, 5⁄16-18, .180 Grip, ZC

33 2 91253A723 Bolt, 1⁄2-13 x 23⁄4”, GSHCS, BP

36

00135546 Air Line Kit, Air Suspension

Black air lines are air system supply.Green air lines are air system discharge.


1 16’ C606-BLACK Tubing, Air Brake, 3⁄8”, Black

2 25’ C604-BLACK Tubing, Air Brake, 1⁄4”, Black

3 20’ C604-GREEN Tubing, Air Brake, 1⁄4”, Green

4 16’ LM3/8NBLK Loom, Split, 3/8”, Black

5 45’ LM1/4NBLK Loom, Split, 1/4”, Black

6 40 0JJS Cable Tie, 50#, 73⁄4”, Black

37

OPTIONAL EQUIPMENT

Tru-Ride Air Suspension

38


1 1 04632A8 On-Spot Chain System (Refer to pages 38-39 for parts)

2 1 00130305 Assembly Kit, On-Spot (Refer to pages 40-41 for parts)

On-Spot Tire Chains

OPTIONS - ON-SPOT TIRE CHAINS

39


Model 04632A8

40


TO AIR SYSTEM MANIFOLD

TO AIR COMPRESSOR OUTLET

TO ON-SPOTS

24171819ON-SPOT AIR TANK

6 11 14

8 10 12

7 10 12

5913

4

3

12

22 16

21

23

15

20

MAIN AIR TANK

00130305 Assembly Kit, On-Spot Tire Chains

41


00130305 Assembly Kit, On-Spot Tire Chains


1 1 00108387 Air Tank, 8” O.D. x 24”

2 1 00129288 Bracket, Mounting, Tank, On-Spot, FR

3 1 00129289 Bracket, Mounting, Tank, On-Spot, RR

4 1 00129298 Bracket, Mounting, Solenoid, On-Spot

5 2 05010593 Bolt, 1⁄4-20 x 1”, G8, HHCS, ZC

6 4 05010644 Bolt, 3⁄8 -16 x 11⁄4”, G8, HHCS, ZC

7 3 05010692 Bolt, 1⁄2-13 x 13⁄4”, G8, HHCS, ZC

8 1 05010693 Bolt, 1⁄2-13 x 2”, G8, HHCS, ZC


10 4 05020847 Nut, 1⁄2-13, GC, Top Lock, C&W

11 4 05020912 Nut, 3⁄8 -16, G8, Nylon Lock, ZC


13 4 05021305 Washer, 1⁄4”, Flat, ZC

14 4 05021307 Washer, 3⁄8”, Flat, ZC

15 1 3149-6 Plug, Countersunk, 3⁄8” MNPT

16 1 3220-6-4 Bushing, 3⁄8” MNPT x 1⁄4” FNPT

17 1 3327-06-2 Nipple, Long, 3⁄8” NPT x 2”

18 1 3750-6 Tee, Street, 3⁄8” NPT

19 1 AQ68-DOT-6X6 Connector, 3⁄8” Air x 3⁄8” MNPT

20 2 AQ69-DOTS-6X6 Elbow, 90˚, Swivel, 3⁄8” Air x 3⁄8” MNPT

21 1 HT-1047 Mounting Kit, Air Tank, 8” O.D.

22 1 S9343150470 Drain Valve, 1⁄4” MNPT, 24” Cable

23 1 N1178AB Relief Valve, 150 PSI, 3⁄8” NPT

24 1 PV2668C Valve, Protection, Pressure

42


On-Spot Tire Chains, Air Schematic

43

OPTIONS - AIR DRYER KIT


1 1 00126515 Harness Assembly, Air Dryer (Refer to page 24 for schematic)

2 1 00135544 Bracket, Mounting, Air Dryer

3 2 05010619 Bolt, 5⁄16-18 x 11⁄4”, G8, HHCS, ZC


5 4 05021306 Washer, 5⁄16”, Flat, ZC

6 3 05021307 Washer, 3⁄8”, Flat, ZC

7 1 13241 Switch Assembly, Low Air Pressure


9 1 AD-DU4-58270 Air Dryer


11 3 XXV4 Bolt, M10-1.25 x 25, G10.9, HHCS, ZC

12 1 05016955 Screw, #10-24 x 3⁄4”, PH RD HD, ZC

13 1 05020507 Nut, #10-24, G2, Nylon Lock, ZC

14 1 05021328 Washer, #10, Flat, ZC

2

78

9

11 6

10

12 13 14

3 4 5

ATTACH RELAY IN AIR COMPRESSOR ENCLOSURE

00135541 Air Dryer Kit, Ram 4500/5500

44

OPTIONS - ENHANCED PING TANK

00136048 Ping Tank Kit, Enhanced, Ram

21 24 19 26

30

18 35

20 22 18 29

27

28

6 11 14

1

36

31012

34

161x RH SPRING ARM MTG BRACKET

2x LEVELING VALVES

151284

COMPRESSOR ENCLOSURE

17

25913

25

AIR COMPRESSOR ENCLOSURE MTG CONFIGURATION

1CROSSMEMBER MTG CONFIGURATION

2323

BUSHINGS FOUND IN TANK/CHASSISASSY KIT, P/N 00129215

6 11 14

7 11 14

45


1 2 00114443 Air Tank, 6” O.D. x 18”

2 1 00136047 Mounting Kit, Ping Tank, Ram (Refer to page 46 for parts)

3 4 05010591 Bolt, 1⁄4-20 x 3⁄4”, G8, HHCS, ZC

4 2 05010593 Bolt, 1⁄4-20 x 1”, G8, HHCS, ZC

5 2 05010619 Bolt, 5⁄16-18 x 11⁄4”, G8, HHCS, ZC

6 11 05010644 Bolt, 3⁄8 -16 x 11⁄4”, G8, HHCS, ZC

7 4 05010645 Bolt, 3⁄8-16 x 11⁄2”, G8, HHCS, ZC



10 4 05020899 Nut, 1⁄4-20, GC, Top Lock, C&W

11 15 05020912 Nut, 3⁄8 -16, G8, Nylon Lock. ZC

12 6 05021305 Washer, 1⁄4”, Flat, ZC

13 4 05021306 Washer, 5⁄16”, Flat, ZC

14 30 05021307 Washer, 3⁄8”, Flat, ZC

15 2 25110 Clamp, Cable, Insulated, #10

16 3 25112 Clamp, Cable, Insulated, #12

17 2 3149-8 Plug, 1⁄2” NPT


19 2 3325-6-4 Nipple, Hex, 3⁄8” NPT x 1⁄4” NPT

20 2 3325-8-8 Nipple, Hex, 1⁄2” NPT

21 2 3700-6 Tee, Union, 3⁄8” NPT

22 2 501A-3-12-20 Air Valve, Ping Tank






28 2 AQ72-DOTS-4X2 Tee, Branch, Swivel, 1⁄4” Air x 1⁄8” MNPT



31 4’ C604-BLACK Tubing, Air Brake, 1⁄4”, Black (Not Shown)

32 4’ C604-GREEN Tubing, Air Brake, 1⁄4”, Green (Not Shown)

33 12’ C608-BLACK Tubing, Air Brake, 1⁄2”, Black (Not Shown)

34 1 MTE-405 Tag, Stop-Quick Recovery Air

35 2 S9343150470 Drain Valve, 1⁄4” MNPT, 24” Cable

36 2 WM-87 Valve, Press Protection, Adjust


00136048 Ping Tank Kit, Enhanced, Ram

45

46


1122

33

44

55


1 2 00129293 Spacer, Enclosure, Ping Tank

2 1 00129296 Bracket Weldment, Enclosure, Ping Tank

3 1 00129297 Bracket, Press Protection, RH

4 1 00130300 Bracket, Press Protection, LH

5 1 00136046 Bracket Weldment, Mounting, Ping Tank, RR

00136047 Mounting Kit, Ping Tank, Ram

OPTIONS - ENHANCED PING TANK & DRYER

Air Schematic, Enhanced Ping Tank & Dryer

47

11

2, 5

33

4, 2

6

4, 2

620

, 11

, 8,

18

20,

11,

8, 1

8

17

29

17

17

29

17

14,

9

24

7, 2

5

23

30

30

24

10,

23

23

19

7, 2

5

6, 2

8

6, 2

8

6, 2

8

27

6, 2

1

21,

12

156

6, 1

3

1416

22

22

48

OPTIONS - UNDER CAB COMPRESSOR

1

25

34

00132568 Mounting Kit, Compressor, Inner Frame


1 1 00131503 Bracket Weldment, Air System, Inner

2 1 05010645 Bolt, 3⁄8-16 x 11⁄2”, G8, HHCS, ZC

3 3 05010691 Bolt, 1⁄2-13 x 11⁄2”, G8, HHCS, ZC



49

00126515 Harness Assembly, Air Dryer


50


Air Dryer Kit, Air Schematic


Air Dryer Kit, Electrical Schematic

51

52

1051 West 7th StreetMonroe, WI 53566

608-328-8127 • 800-356-8134

Truck Equipment Installation & Modifications Limited Warranty

Monroe Truck Equipment Limited WarrantyAll components and products manufactured and installed by Monroe Truck Equipment (MTE) are warranted to be free from defects in material andworkmanship for either (1) year from the date of purchase or (1) year from the date that the vehicle was put in service by its original operator, or12,000 miles whichever occurs first.

All MTE workmanship, whether installation of MTE products or purchased components, fabrication, or repair, is covered for the same 12 month/12,000mile warranty.

This limited warranty is the sole and exclusive remedy for defective product manufactured and/or installed by MTE.

This limited warranty covers only components manufactured by MTE. Except for installation workmanship, this limited warranty does not pertain tocomponents manufactured by non-MTE suppliers and purchased by MTE, regardless of whether these components were selected or recommended byMTE.

Purchased Materials and Components WarrantyMTE sells and installs many components manufactured by and purchased from other suppliers. These components are covered by the warranty poli-cies of the individual suppliers. MTE will, as a service to the buyer, pass on any warranties received from the manufacturer of these components andwill process warranty claims related to supplier products. Unless the end user chooses to work directly with a non-MTE component supplier, MTEshall act as intermediate between the end user and the component supplier.

Non-MTE supplier policies typically differ from the MTE limited warranty. MTE has no control over the warranty policies of other suppliers and shall notdeviate from a supplier’s warranty without express written permission from that supplier.

Any and all claims concerning non-MTE components must be forwarded to MTE within 10 days of the discovered defect. All documentation of saidclaims must be accompanied with the identification number of the vehicle and/or a copy of the invoice. MTE has, at their option, a choice of whetherto repair or replace the defective part at a MTE repair center or a location approved by MTE unless otherwise specified by the manufacturer.

Peripheral, Incidental, and Consequential Damages and ClaimsThe MTE limited warranty does not apply to damage and failure resulting from misuse, abuse, neglect, accident, improper customer/distributor installa-tion, 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 thiswarranty. Operating conditions, or applications not made known to or contemplated by MTE at the time of delivery to the buyer may also void this war-ranty. Damages resulting from any other abnormal operation will not be covered by this warranty.

Normal maintenance, wear, and consumable items such as oils, coolants, fluids, tires, belts, hoses, filters, air cleaners, and light bulbs supplied in con-nection with goods or services provided by MTE 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 payfor 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.

Warranty Repairs Performed by MTE or Authorized AgentsWhenever possible and feasible, warranty repairs shall be performed at an MTE facility or at an authorized distributor or dealer. In some instances, anMTE Field Service representative may repair the vehicle at the owner’s selected location.

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.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, road testing,or delivery to the end user location, nor for lost time incurred by an owner delivering and picking up a vehicle.

Warranty Repairs Performed by Non-MTE EntitiesIn certain circumstances, MTE may authorize the vehicle owner, a dealer, a distributor, or another third party to perform warranty repairs. MTE willthen reimburse the entity performing the work for components used and for labor to perform the repairs. Any such decision will be based on type ofrepair, distance to the nearest approved MTE repair site, and urgency of the repair.

Except for emergencies, MTE must grant authorization and permission before a non-MTE entity begins repair or replacement of compo-nents. Warranty claims for unauthorized and unsubstantiated work may be denied.If MTE authorizes the buyer or a third party to repair or replace the defective parts instead of MTE doing such work itself, the buyer shall be invoicedfor the replacement parts. Credit will be given pending the return of the defective parts and warranty issued by manufacturer. Authorized warrantywork not performed by MTE will be at the rate of $43.50/hr, and invoices for authorized work will be paid net 30. In the event that MTE and the sec-ond party cannot come to an agreement, a binding third party arbitrator will be chosen with the mutual consent of both parties.

Electrical and hydraulic components are not to be disassembled without the express written consent of MTE. All defective parts returned must be accom-panied by the manufacturers’ model, serial number, and date of installation. Any parts returned for warranty must by returned with freight prepaid.

53

How to Obtain Warranty Service from Monroe Truck Equipment

Making an Appointment for Warranty Service at an MTE Facility or Authorized Repair Site1. Obtain the following information:

• Vehicle Identification Number (VIN)

• Type, model, and serial number of component or product requiring service

• Number of original MTE Sales Order if available

• Name of dealer that vehicle was purchased from if known

• Date of purchase/in-service date if known

• 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.• Monroe, Wisconsin: 1-608-329-8437 (Warranty Dept.) or 1-800-356-8134 (ask for Warranty Dept.)

• Flint, Michigan: 1-877-233-2030 (ask for Warranty Dept.)

• De Pere, Wisconsin: 1-800-848-5400 (ask for Service Dept.)

• Marshfield, Wisconsin: 1-800-882-1900 (ask for Service Dept.)

• Joliet, Illinois: 1-800-892-7052 (ask for Service Dept.)

• Louisville, Kentucky: 1-502-426-0990 (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 Performed1. Obtain the following information:

• All of the information requested in item #1 above, plus:

• Documented photographs for any physical damage. (paint, dents, etc.)

• 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: 06/19/09

1051 West 7th StreetMonroe, WI 53566

608-328-8127 • 800-356-8134

MONROE TRUCK EQUIPMENT1051 W. 7th Street • Monroe, WI 53566800-356-8134 • www.monroetruck.com

MTE Tru-Ride Air Suspension Owner’s Manual Ram 4500/5500€¦ · The specified ride height sets...

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Transcript of MTE Tru-Ride Air Suspension Owner’s Manual Ram 4500/5500€¦ · The specified ride height sets...