Ford - F 550 - Owners Manual - 2012 - 2012

MTE Tru-Ride Air Suspension Owner’s Manual Ford F450/F550 • Operation • Maintenance • Troubleshooting • Service Parts MONROE TRUCK EQUIPMENT 1051 W. 7th Street • Monroe, WI 53566 800-356-8134 • www.monroetruck.com 05090605 12/20/12 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 Ford F450/550 Super Duty Manual # 05090605 Revision Level December 20, 2012 Copyright © 2012 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-53 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-55 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 sight. WARNING 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 supplied. CAUTION If a fuse burns out, investigate and repair the cause. 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. CAUTION If the shock absorbers are disconnected, the rear axle must be supported on stands while the vehicle is raised. 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 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 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” 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 when the suspension is at rest. CAUTION Over or under-inflation of the air bags will result in rough ride and poor handling, and may permanently damage the bags. 3 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 suspension 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 inflate. 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 suspension 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. On ambulance applications where the “dump” function is controlled by switches at the rear doors, the ambulance body installer is responsible for all controls and wiring. NOTE MTE is typically not involved in the installation or wiring of ambulance bodies. 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.  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 added 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 moving the vehicle a short distance.  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 vehicle to be moved to a repair location. CAUTION 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 retightened after the first 1,000 miles of operation. CAUTION 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 compressor 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 Replace at 50,000 miles. Inspect suspension components and bushings X Initial inspection after first 1,000 miles. Inspect condition of air bags X Tighten suspension component fasteners X Initial check after first 1,000 miles. Tighten every 25,000 miles or annually. 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. 6 Routine Maintenance—Ford 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 fasteners. If zinc-plated nuts 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. Fastener Application Description Torque, ft/lbs. Comments Zinc plated Cad plated (yellow) (silver) 1/2-13 hex-head and flat socket head bolts 25 n/a Non-standard torque value. Overtightening may damage air bag. 1/2-13 nut, flanged top-lock 30 n/a Non-standard torque value. Overtightening may damage air bag. Frame bracket mounting bolts, all 3/8" dia. 3/8-16 hex head bolt, black phosphate w/flanged top-lock nut 37 27 Frame bracket mounting bolts, all 1/2" dia. 1/2-13 hex head bolt, black phosphate w/flanged top-lock nut 80 70 Lower air spring plate brace 1/2-13 hex head bolt, black phosphate w/flanged top-lock nut 80 70 Frame bracket mounting bolts 5/8-11 hex head bolt, black phosphate w/flanged top-lock nut 160 119 Torque arm axle bracket 5/8-11 hex head bolt, black phosphate w/flanged top-lock nut 160 119 Spring arm axle clamp bolts 3/4-10 bolt, zinc plated, w/flanged top-lock nut 280 200 Spring arm eye bolts 3/4-10 bolt, zinc plated, w/flanged top-lock nut 280 200 Torque arm eye bolts 5/8-11 hex-head flanged bolt, zinc plated, w/flanged top-lock nut 167 120 Shock absorber, top mounting nut 12-1.75 mm hex head bolt w/toplock nut 60 n/a Standard OEM fastener Shock absorber, bottom mounting bolt 12-1.75 mm hex head bolt w/toplock nut 60 n/a Standard OEM fastener Air bag, bottom bolt Air bag, top studs 7 Cad-plated nuts supplied and recommended. Tighten evenly and progressively in torque increments. Routine Maintenance—Ford Fastener Tightening Torque values given here are based on the standard fasteners supplied with the original installation kit:  Grade 8  Flanged bolts and nuts for framemounted brackets.  Steel top-lock nuts and hardened flat washers  Most nuts supplied originally are cadmium-plated and waxed Any changes to fastener specifications will also change required tightening torque. NOTE If fasteners are replaced, use only the same size, grade, and type of fastener originally supplied. NOTE All fasteners must be tightened and checked with a tested and calibrated torque wrench. 8 Repairs  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. 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. CAUTION If the shock absorbers are disconnected, the rear axle must be supported on stands while the vehicle is raised. 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 equipment repair shop. NOTE 9 Troubleshooting—Suspension Refer to the Air Compressor Owner’s manual for information on troubleshooting air compressor system problems. NOTE Problem Possible Causes Solutions Air bags do not inflate—bags deflated 1. 2. 3. 4. 1. Turn Dump function off. 2. Refer to troubleshooting instructions for air compressor. 3. Check for and repair leaks. 4. Reconnect link rod(s), adjust ride height if required. 5. Inspect all air hose routings, repair any kinks or blockages. One air bag deflated 1. Air bag ruptured, leaking. 1. Check for air leaks at bag, replace if ruptured. 2. Leveling valve for bag dis2. Check leveling valve link rod. connected or defective. Reconnect and adjust. Re3. Air hose to bag kinked or place valve if defective. 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. 2. Leveling valve arm or link rod bent. 3. Defective leveling valve. 4. Suspension component bent or damaged. 1. Adjust link rod(s) as required to achieve proper height. 2. Repair or replace valve or link rod, then adjust for proper 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. Suspension does not respond when weight is added or removed from chassis. 1. Leveling valve link rod(s) disconnected. 2. Leveling valve defective. 1. Reconnect link rod(s), adjust ride height if required. 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. 2. Shock absorbers worn out. 1. Set shocks to higher firmness setting. 2. Replace shocks. Dump (kneel) switch on. Compressor unit failure. Large air leak in system. Leveling valve link rod(s) disconnected. 5. Pinched or kinked air hose between air tank and leveling valve(s) 10 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 1. 2. 3. 4. Tires over-inflated. Ride height set too low. Ride height set too high. Shock absorber settings too high. 1. Check and adjust tire pressures. 2. Adjust ride height. 3. Adjust ride height. 4. Check and adjust shock absorber settings. Soft, mushy ride, poor handling. 1. Tires underinflated. 2. Ride height set too low. 3. Shock absorbers worn out. 4. Worn out bushing in suspension components. 1. Check and adjust tire pressures. 2. Adjust ride height. 3. Replace shock absorbers. 4. Inspect and replace bushings. Optional Quick-Recovery does 1. Air valves not adjusted not work or is too slow properly. 2. Defective air valve(s). 3. Air leak in system. 11 1. Adjust air valves per instructions. 2. If valve adjustment does not work, replace valve(s). 3. Check all air circuits for leaks. Electrical Schematic 12 Air Schematic 13 Adjusting Ride Height Suspension components can be damaged 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 specified ride height regardless of load weight. The specified ride height sets the inflatable air bags at their mid-point of travel when the suspension is at rest. CAUTION 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 handling, and may permanently damage the bags. 14 Adjusting Ride Height (Cont’d) Look Action Task 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. 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. CAUTION Make sure there is enough air in the bags to raise the chassis a few inches. 4. 15 Verify that the air bags are fully inflated and the compressor pump has stopped. Adjusting Ride Height (Cont’d) Look Action H Task 5. Verify that the system air pressure is 120 psig with the compressor off. Check the system pressure at the primary tank emergency fill using a truck tire gauge. 6. Measure the distance between the underside 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 8. 16 7.0” If the ride height requires adjustment, loosen both lock nuts at the adjuster rod. Adjusting Ride Height (Cont’d) Look Action Task For systems with dual leveling valves, the valves must be adjusted individually for each side. NOTE After initially setting both valves, check the ride height again and make minor adjustments as necessary. 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. When adjusting the length of the leveling rod, make equal changes at each end of the rod. NOTE 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 minimum 1/4” thread makeup in the plastic 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 17 Adjusting Ride Height (Cont’d) Look Action Task 11. Reinstall the top pivot stud in the valve arm and check the ride height. Readjust 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. 18 Adjusting Quick-Recovery Air Valves 19 Adjusting Quick-Recovery Air Valves The “Quick-Recovery” system is an optional feature that may not be installed 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. NOTE If desired, the Quick-Recovery system can be retrofitted to any MTE air suspension system. Contact MTE Sales for more information. 20 Adjusting Quick-Recovery Air Valves (Cont’d) Look Action Task A body and all other permanentlyinstalled equipment must be installed before the Quick-Recovery valves are adjusted. The full weight of the completed installation must be on the rear suspension for proper valve adjustment. NOTE Do not attempt to adjust the QuickRecovery valves on an unfinished cab chassis. 21 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. 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. Adjusting Quick-Recovery Air Valves (Cont’d) Look Action Task 7. Loosen the lock nuts on the valve adjuster bolts and turn the bolts nearly all the way out. 8. Activate the “Dump” function. 9. Verify that the air bags deflate and the chassis settles all the way down on the bump stops. Loosen 22 Adjusting Quick-Recovery Air Valves (Cont’d) Look Action Task Bumps stops are inside the air springs on a Ford SD installation. 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. 11. Shut off the “Dump” function and allow the air bags to fill and the vehicle to reach the normal ride height. 23 Adjusting Quick-Recovery Air Valves (Cont’d) Look Action Task 12. Turn both Quick Recovery valve adjuster bolts about 1/3 of the way in. Leave the lock nuts loose at this time. 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 between 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 adjusted properly. 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 residual pressure in the system is what provides quick recovery to the normal ride height. NOTE By measuring and adjusting the “kneel” height, it is not necessary to try to achieve a specific system air pressure in the “dump” mode. 24 Adjusting Quick-Recovery Air Valves (Cont’d) 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. 33” 18. Adjust the Quick Recovery valves as required to achieve the “kneel” height of 1/4” to 1/2” higher than the fully deflated 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. Raise 20. If the suspension is too high, turn the adjuster bolts out slowly while still in the “dump” mode to achieve the required “kneel” height. Lower 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 deactivated and the suspension raised to the normal ride height before adjusting the valves. Once the air dump is complete, turning the adjuster bolts in will not add air to the system. NOTE 25 Adjusting Quick-Recovery Air Valves (Cont’d) Look Action Task 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 26 Service Parts Ford F450/F550 Tru-Ride Air Suspension 27 This page left blank intentionally. 28 TRURIDE AIR SUSPENSION, FORD F450/F550 Item Qty Part Number Description 1 1 00146870 Mounting Kit, Air Suspension, Ford, 2013 See page 30 2 1 00146873 Assembly Kit, Air Suspension, Ford, 2013 See page 32 3 1 00129216 Air System Assembly, Ford (Refer to Parts Manual #05090448 for parts & service) 3 1 2 29 00146870 Mounting Kit, Suspension, Ford 14 10 7 15 9 19 6 8 1 11 5 3 17 20 18 4 2 16 12 13 30 00146870 MOUNTING KIT, SUSPENSION, FORD, 2013 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 QTY 2 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 PART NUMBER 00126557 00126560 00126568 00126569 00126575 00126594 00126597 00127767 00127769 00127778 00127780 00129258 00129259 00129262 00129265 00129275 00129292 00131537 00146856 00146861 DESCRIPTION ADAPTER ASSY,SPRING CLAMP BOTTOM PL WLDMT,LH BOTTOM PL WLDMT,RH MTG PL WLDMT,AIR SPRING,LH BRACE WLDMT,AIR SPRING,LOWER BRACKET WLDMT,AIR SPRING,LH BRACKET,MTG,LEVELING VALVE MTG PL WLDMT,AIR SPRING,RH BRACKET WLDMT,AIR SPRING,RH BRACKET WLDMT,SPRING ARM,RH BRACKET WLDMT,SPRING ARM,LH BRACKET,BRAKE LINE,AXLE,OUTER BRACKET,BRAKE LINE,AXLE CRADLE BRACKET WLDMT,MTG,AIR TANK,FR BRACKET WLDMT,MTG,AIR TANK,RR CRADLE WLDMT,AXLE,LOWER BRACKET,BRAKE CABLE BRACKET,MTG,SENSOR CONTROLLER BRACKET WLDMT,TORQUE ARM,FRAME CRADLE WLDMT,AXLE,UPPER 31 00146873 Assembly Kit, Air Suspension, Ford, 2013 5 6 8 7 11 1 4 2 9 13 10 32 12 00146873 ASSEMBLY KIT, AIR SUSPENSION, FORD, 2013 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 QTY 2 2 1 2 2 1 1 1 2 1 1 1 4 PART NUMBER 00108307 00111428 00135546 00125688 00126591 00146871 05090605 05090448 15640806 00146854 BR630 BR631 W01-358-5379 DESCRIPTION SPRING ARM ASSY LINKAGE ASSY,RH/LH See page 34 AIR LINE KIT,AIR SUSPN,2011 - NOT SHOWN VALVE ASSY,LEVELING,AIR RIDE SHOCK ASSY,F450/550 HARDWARE KIT,AIR SUSPN,FORD See page 36 MANUAL,AIR SUSPENSION,FORD MANUAL,AIR COMPRESSOR,FORD MTG BLOCK,AXLE,5 DEGREE,OEM TORQUE ARM ASSY,23.250 LABEL,FORD AIR RIDE LABEL,LOW AIR PRESSURE AIR SPRING ASSY,FORD 33 See page 35 4 5 2 3 00111428 LINKAGE ASSY, RH/LH ITEM 1 2 3 4 5 QTY 1 1 1 1 1 PART NUMBER BM 6 00108339 05020995 BM 6LH 05020995-LH DESCRIPTION ROD END ASSY,M6-1.0 LINKAGE,M6-1.0 x 160 MM ZC NUT M6-1 CLS8.8 HHCS ZC ROD END ASSY,M6-1.0,LH NUT M6-1 CLS8.8 HHCS ZC LH 34 1 00135546 Air Line Kit, Air Suspension 00135546 AIR LINE KIT, AIR SUSPENSION ITEM 1 2 3 4 5 6 QTY 16' 25' 20' 16' 45' 40 PART NUMBER C606-BLACK C604-BLACK C604-GREEN LM3/8NBLK LM1/4NBLK 0JJS DESCRIPTION TUBING,AIR BRAKE,3/8",BLACK TUBING,AIR BRAKE,1/4",BLACK TUBING,AIR BRAKE,1/4",GREEN LOOM,SPLIT,3/8" BLACK LOOM,SPLIT,1/4" BLACK CABLE TIE,50#,7 3/4",BLACK Black air lines are air system supply. Green air lines are air system discharge. 35 00146871 Hardware Kit, Air Suspension, Ford, 2013 7 20 13 BRAKE CABLE BRACKET 25 16 21 2x - SPRING ARM MTG BRACKET 3 4 17 24 2x - LEVELING VALVE MTG BRACKET 12 2x - LOWER AIR SPRING MTG 7 7 2x - SPRING ARM MTG 22 10 20 RH AIR SPRING MTG BRACKET 20 2x - UPPER AIR SPRING MTG 7 12 7 20 20 LH AIR SPRING MTG BRACKET 8 6 2x - SPRING ARM AXLE MTG 22 11 14 2x - LOWER AIR SPRING BRACE 20 19 21 TORQUE ARM MTG 9 23 15 2 BRAKE LINE AXLE BRACKETS 23 15 1 AXLE VENT TUBE MTG BLOCK 27 36 18 26 5 20 20 AXLE CRADLE MTG BRACKETS TORQUE ARM FRAME MTG BRACKET 00146871 HARDWARE KIT, AIR SUSPENSION, FORD, 2013 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 QTY 1 2 4 2 8 1 25 3 4 4 8 3 4 2 3 2 4 1 1 48 8 12 6 8 4 2 1 PART NUMBER 05010591 05010593 05010618 05010644 05017072 05017094 05017097 05017098 05017102 05017105 05017151 05017152 05017154 05017208 05020536 05020898 05020909 05020985 05021097 05021098 05021099 05021100 05021305 05021306 05021307 WS84 YWZC DESCRIPTION BOLT .250-20 x .750 G8 HHCS ZC BOLT .250-20 x 1.00 G8 HHCS ZC BOLT .313-18 x 1.00 G8 HHCS ZC BOLT .375-16 x 1.25 G8 HHCS ZC BOLT .500-13 x 2.25 G8 HFHS BP BOLT .375-16 x 1.50 G8 HFHS BP BOLT .500-13 x 1.50 G8 HFHS BP BOLT .500-13 x 1.75 G8 HFHS BP BOLT .500-13 x 2.75 G8 HFHS BP BOLT .750-10 x 3.00 G8 HFHS BP BOLT .750-10 x 13.0 G8 HHCS ZC BOLT .500-13 x 2.00 FSHCS BP BOLT .625-11 x 1.75 G8 HFHS BP BOLT .625-11 x 3.50 G8 HFHS BP NUT .250-20 G2 NYLON LOCK ZC NUT .375-16 GC TOPLOCK C&W NUT .313-18 GC TOPLOCK C&W NUT .438-14 GC TOPLOCK C&W NUT .375-16 GG HF TOPLOCK C&W NUT .500-13 GG HF TOPLOCK C&W NUT .625-11 GG HF TOPLOCK C&W NUT .750-10 GG HF TOPLOCK C&W WASHER .250 FLAT ZC WASHER .313 FLAT ZC WASHER .375 FLAT ZC WASHER .438 FLAT MIL-CARB SAE BOLT .438-14 x 1.50 G8 HHCS ZC 37 38 OPTIONAL EQUIPMENT Tru-Ride Air Suspension 39 OPTIONS - ON-SPOT TIRE CHAINS On-Spot Tire Chains Item Qty Part Number Description 1 1 04632A8 On-Spot Chain System (See below) 2 1 00130305 Assembly Kit, On-Spot, Ford (See page 42) 40 OPTIONS - ON-SPOT TIRE CHAINS Model 04632A8 41 OPTIONS - ON-SPOT TIRE CHAINS 6 11 8 10 12 7 10 12 14 TO AIR COMPRESSOR OUTLET 3 2 ON-SPOT AIR TANK 1 13 9 5 4 21 MAIN AIR TANK 15 19 15 16 17 24 20 22 18 TO ON-SPOTS TO AIR SYSTEM MANIFOLD 42 23 OPTIONS - ON-SPOT TIRE CHAINS 00130305 ASSEMBLY KIT, ON-SPOT TIRE CHAINS, FORD ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 QTY 1 1 1 1 2 4 3 1 2 4 4 8 4 4 2 1 1 1 1 1 1 1 1 1 PART NUMBER 00108387 00129288 00129289 00129298 05010593 05010644 05010692 05010693 05020536 05020847 05020898 05021005 05021305 05021307 3149-6 3220-6-4 3325-6-4 3750-6 AQ68-DOT-6X6 AQ69-DOTS-6X6 HT-1047 S9343150470 AQ69-DOTS-6X4 PVA448C DESCRIPTION AIR TANK,8.000 OD x 24.000 BRACKET,MTG,TANK,ON-SPOT,FR BRACKET,MTG,TANK,ON-SPOT,RR BRACKET,MTG,SOLENOID,ON-SPOT BOLT .250-20 x 1.00 G8 HHCS ZC BOLT .375-16 x 1.25 G8 HHCS ZC BOLT .500-13 x 1.75 G8 HHCS ZC BOLT .500-13 x 2.00 G8 HHCS ZC NUT .250-20 G2 NYLON LOCK ZC NUT .500-13 GC TOPLOCK C&W NUT .375-16 GC TOPLOCK C&W WASHER .500 FLAT MIL-CARB SAE WASHER .250 FLAT ZC WASHER .375 FLAT ZC PLUG,COUNTERSUNK,3/8 MNPT BUSHING,3/8 M-NPT,1/4 F-NPT NIPPLE,HEX,3/8 NPT x 1/4 NPT TEE,STREET,3/8 NPT CONNECTOR,3/8 AIR,3/8 M-NPT ELBOW,90,SWVL,3/8 AIR,3/8M-NPT MTG KIT,AIR TANK,8.000 OD DRAIN VALVE,1/4 MNPT,24" CABLE ELBOW,90,SWVL,3/8 AIR,1/4M-NPT VALVE,BRK PROTECTION,1 WAY 43 OPTIONS - ON-SPOT TIRE CHAINS On-Spot Tire Chains, Air Schematic 44 OPTIONS - AIR DRYER KIT 00130304 Air Dryer Kit 12 13 ATTACH RELAY IN AIR COMPRESSOR ENCLOSURE 14 9 2 8 7 11 6 10 00130304 AIR DRYER KIT ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 QTY 1 1 2 2 4 3 1 1 1 2 3 1 1 1 PART NUMBER 00126515 00130302 05010619 05020911 05021306 05021307 13241 3220-4-2 AD-DU4-58270 AQ69-DOTS-6X8 XXV4 05016955 05020507 05021328 DESCRIPTION HARNESS ASSY,AIR DRYER - NOT SHOWN BRACKET,MTG,AIR DRYER BOLT .313-18 x 1.25 G8 HHCS ZC NUT .313-18 G8 NYLON LOCK ZC WASHER .313 FLAT ZC WASHER .375 FLAT ZC SWITCH ASSY,LOW AIR PRESSURE BUSHING,1/4 M-NPT,1/8 F-NPT AIR DRYER ELBOW,90,SWVL,3/8 AIR,1/2M-NPT BOLT M10-1.25x25 G10.9 HHCS ZC SCREW #10-24 x .75 PH RD HD ZC NUT #10-24 G2 NYLON LOCK ZC WASHER #10 FLAT ZC 45 See page 50 OPTIONS - ENHANCED PING TANK 00131550 Ping Tank Kit, Enhanced, Ford 13 9 5 13 3 12 5 2 15 31 19 29 27 30 12 5 9 10 3 25 35 25 13 18 1 14 11 RH FRAME RAIL MTG CONFIGURATION 7 6 8 12 14 30 COMPRESSOR ENCLOSURE 4 11 16 1x RH SPRING ARM MTG BRACKET 2x LEVELING VALVES 29 17 21 29 24 19 31 22 33 23 19 34 CROSSMEMBER MTG CONFIGURATION 32 1 46 26 20 28 OPTIONS - ENHANCED PING TANK 00131550 PING TANK KIT, ENHANCED, FORD ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 QTY 2 1 8 2 6 8 4 2 4 4 12 10 10 24 4 2 3 2 4 2 1 1 2 2 4 2 1 2 3 2 2 2 1 2 2 4' 4' 12' PART NUMBER 00114443 00131549 05010591 05010593 05010619 05010644 05010646 05020536 05020537 05020899 05020912 05021305 05021306 05021307 05021363 25110 25112 3149-8 3220-8-4 3325-6-4 3325-8-8 3400-8 3700-6 501A-3-12-20 AQ68-DOT-4X6 AQ68-DOT-8X6 AQ68-DOT-8X8 AQ69-DOTS-4X6 AQ69-DOTS-8X8 AQ72-DOTS-4X2 AQ72-DOTS-4X4 AQ72-DOTS-8X4 MTE-405 S9343150470 WM-87 C604-BLACK C604-GREEN C608-BLACK DESCRIPTION AIR TANK,6.000 OD x 18.000 MTG KIT,PING TANK,2011 See page 48 BOLT .250-20 x .750 G8 HHCS ZC BOLT .250-20 x 1.00 G8 HHCS ZC BOLT .313-18 x 1.25 G8 HHCS ZC BOLT .375-16 x 1.25 G8 HHCS ZC BOLT .375-16 x 1.75 G8 HHCS ZC NUT .250-20 G2 NYLON LOCK ZC NUT .313-18 G2 NYLON LOCK ZC NUT .250-20 GC TOPLOCK C&W NUT .375-16 G8 NYLON LOCK ZC WASHER .250 FLAT ZC WASHER .313 FLAT ZC WASHER .375 FLAT ZC WASHER .250 LOCK ZC CLAMP,CABLE,INSULATED,#10 CLAMP,CABLE,INSULATED,#12 PLUG,1/2 NPT BUSHING,1/2 M-NPT,1/4 F-NPT NIPPLE,HEX,3/8 NPT x 1/4 NPT NIPPLE,HEX,1/2 NPT ELBOW,90,STREET,1/2 NPT TEE,UNION,3/8 NPT AIR VALVE,PING TANK CONNECTOR,1/4 AIR,3/8 M-NPT CONNECTOR,1/2 AIR,3/8 M-NPT CONNECTOR,1/2 AIR,1/2 M-NPT ELBOW,90,SWVL,1/4 AIR,3/8M-NPT ELBOW,90,SWVL,1/2 AIR,1/2M-NPT TEE,BRANCH,SWVL,1/4AIR,1/8MNPT TEE,BRANCH,SWVL,1/4AIR,1/4MNPT TEE,BRANCH,SWVL,1/2AIR,1/4MNPT TAG,STOP-QUICK RECOVERY AIR DRAIN VALVE,1/4 MNPT,24" CABLE VALVE,PRESS PROTECTION,ADJUST TUBING,AIR BRAKE,1/4",BLACK - NOT SHOWN TUBING,AIR BRAKE,1/4",GREEN - NOT SHOWN TUBING,AIR BRAKE,1/2",BLACK - NOT SHOWN 47 OPTIONS - ENHANCED PING TANK 00131549 Mounting Kit, Ping Tank, Enhanced 3 4 2 5 1 00131549 MOUNTING KIT, PING TANK, ENHANCED ITEM 1 2 3 4 5 QTY 2 1 1 1 1 PART NUMBER 00129267 00129297 00130300 00131546 00131547 DESCRIPTION BRACKET,MTG,PING TANK,FRAME BRACKET,PRESS PROTECTION,RH BRACKET,PRESS PROTECTION,LH BRACKET WLDMT,PING TANK,LH BRACKET WLDMT,PING TANK,RH 48 20, 11, 8, 18 20, 11, 8, 18 4, 26 4, 26 17 17 29 29 17 17 49 1 6, 28 1 3 10, 23 23 14 14, 9 24 24 19 7, 25 7, 25 23 6, 28 30 30 3 2, 5 22 16 22 21, 12 15 6 6, 21 6, 28 6, 13 27 OPTIONS - ENHANCED PING TANK & DRYER Air Schematic, Enhanced Ping Tank & Dryer OPTIONS - AIR DRYER KIT 00126515 Harness Assembly, Air Dryer 50 OPTIONS - AIR DRYER KIT Air Dryer Kit, Air Schematic 51 OPTIONS - AIR DRYER KIT Air Dryer Kit, Electrical Schematic 52 OPTIONS - UNDER CAB COMPRESSOR 00131538 Mounting Kit, Under Cab Compressor 8 9 10 ATTACH TO EXHAUST HANGER BOLT REAR CAB CROSSMEMBER 3 6 7 8 8 6 1 FRAME BOLT IN STANDARD KIT USE EXISTING FRAME HOLE 7 6 5 DRILL NEW HOLE FRAME BOLT IN STANDARD KIT DRILL NEW HOLE 4 6 7 RH REAR CAB MOUNT REAM EXISTING HOLE 4 6 7 2 FRAME BOLT IN STANDARD KIT 00131538 MOUNTING KIT, UNDER CAB COMPRESSOR ITEM 1 2 3 4 5 6 7 8 9 10 QTY 1 1 1 2 1 5 8 3 1 1 PART NUMBER 00131539 00131542 05010644 05010645 05010648 05020898 05021013 25724 05021306 05021058 DESCRIPTION MTG PL,COMPRESSOR,FRONT BRACKET WLDMT,COMPRESSOR,RR BOLT .375-16 x 1.25 G8 HHCS ZC BOLT .375-16 x 1.50 G8 HHCS ZC BOLT .375-16 x 2.25 G8 HHCS ZC NUT .375-16 GC TOPLOCK C&W WASHER .375 FLAT MIL-CARB SAE CLAMP,CABLE,INSULATED,#24,HD WASHER .313 FLAT ZC NUT M8-1.25 HEX ZC 53 54 55 MONROE TRUCK EQUIPMENT 1051 W. 7th Street • Monroe, WI 53566 800-356-8134 • www.monroetruck.com