KEIYSHOLCK 57288 Rear Air Spring Bag Suspension Kits Instruction Manual

KEIYSHOLCK 57288 Rear Air Spring Bag Suspension Kits Instruction Manual

Thank you for purchasing the 7X 57288 Kit! Please kindly be advised to read the instructions carefully before installing the air spring kit.

Please take safety precautions accordingly during installation.

The installation instructions are based on the left side or based on the driver’s side of the vehicle, and the structure on the right side can refer to the same method on the left side.

The retrofit kit you purchased is a single valve inflation system.

Please note that the air spring will bend and expand under working conditions. Ensure there is enough space for it to work properly and avoid friction between the air spring and other chassis parts.

IDENTIFYING THE DIFFERENCES BETWEEN KITS
Should you need to contact customer service, you will need to know which kit you are inquiring about: standard 7X 57288, 7X 88288 or 7X 89288. The kits are easily identifiable by looking at the roll plates and air lines.

 7X 57288– Zinc-plated steel roll plates and black nylon air lines.
 7X 88288– Black powder-coated roll plates and black nylon air lines.
 7X 89288.– Stainless steel roll plates, braided stainless steel air lines, stainless steel air spring mounting hardware.

Offers two Ultimate Plus upgrade kits:

Braided stainless steel air line and fittings.

Stainless steel roll plates, air spring mounting hardware, braided stainless steel air lines and fittings.

A. Installation Diagram

B. Hardware and Tools Lists

C. Introduction

The purpose of this publication is to assist with the installation and maintenance of the series air spring kits. All L kits utilize sturdy, reinforced, commercial-grade single or double, depending on the kit, convolute bellows.
The air springs are manufactured like a tire with layers of rubber and cords that control growth. kits provide up to 5,000 pounds (2,268kg) of load- leveling support with air adjustability from 5-100 PSI (.34-7BAR).
It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair.

NOTATION EXPLANATION

Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide.
⚠ DANGER INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.
⚠ WARNING INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
⚠ CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY.

D. Installing the 7X 57288 Series System

GETTING STARTED

ASSEMBLING THE AIR SPRINGS

1. Place a 3/8″-16 x 3″carriage bolt (O) through the innermost square hole on the rear side of each lower bracket (B) (Fig. D.12).
   NOTE The radiused (rounded) edge of the roll plate (F) will be toward the air spring so that the air spring is seated inside the roll plate.

2. Install a lower bracket (B) and roll plate (F) on each air spring (E) using two 3/8″-24 x 3/4″ flat-head socket cap screws (S) through the innermost mounting holes (Fig. D.13). Torque the flat-head screws to no more than 20 lb.-ft. (27Nm).

3. Install the 90 degree swivel elbow fitting (R) into the top of each air spring finger-tight. Tighten the swivel fittings an additional one and a half turns (Fig. D.13).

4. Attach the upper roll plates (F) and upper brackets (A) to the air springs (E) using two 3/8″-24 x 7/8″ bolts (T), two 3/8″ lock washers (U) and two 3/8″ flat washers (V) for each assembly (Fig. D.14). Torque bolts to no more than 20 lb.-ft. (27Nm). These brackets are left and right hand specific (Fig. D.15).

5. With the bracket installed, ensure the swivel fitting is less than 7/8″ in height, and if not, tighten the fitting until this height is achieved (Fig. D.16).

INSTALLING THE AIR SPRINGS

⚠ CAUTION

1. Drop the frame to make room to put the assemblies into position.
   ENSURE VEHICLE IS PROPERLY SUPPORTED PRIOR TO BEGINNING INSTALLATION.

2. Place the assemblies on the lower strike plate with the fitting side of the assembly to the outside (wheel side) of the vehicle. Align the tab on the forward clamp bracket (C) with the hole on the front of the lower bracket (B) (Fig. D.17).

3. Insert two carriage bolts (O) on the rear square holes and one carriage bolt on the front square hole of the lower bracket (B) (both sides) (Figs. D.17 & D.18).

4. Thread the 3/8″ flange nuts (N) onto the carriage bolts previously installed. Ensure the front and rear clamps align correctly under the axle jounce bumper strike plate. Torque all flange nuts evenly to 16 lb.-ft. (22Nm).

ATTACHING THE UPPER BRACKETS

There are two ways to attach the upper bracket.
For trucks that do not have a fifth-wheel hitch bracket alongside the frame:

1. Place U-bolts (I) over the frame as pictured on both sides of the vehicle (Fig. D.19).
2. Lower the vehicle or raise the axle while inserting the threaded portions of the U-bolts (I) through the corresponding holes in the upper brackets (A). Install flange nuts (N) finger-tight (Fig. D.20).
3. Adjust the upper bracket (A) as needed to vertically align the air spring with the frame (or as close to perpendicular as possible).
4. Torque all flange nuts (N) to 16 lb.-ft. (27Nm).

For trucks that have fifth-wheel hitch brackets alongside the frame rail:

1. There are holes in the middle of the bracket just forward and behind the jounce bumper mounting cups on the upper bracket (Fig. A.1). Once the upper brackets are in position, drill two 5/16″ holes through the bottom of the frame using the holes as a template and attach the upper brackets using the thread cutting screws (P). Torque all four fasteners to 15 lb.-ft. (20Nm).
2. Reattach the wire harness guards on the front side of the axle. Tighten securely (Fig. D.21).

E. Installing the Air Lines

INSTALLING NYLON AIR LINES

INSTALLING BRAIDED STAINLESS STEEL AIR LINES

F. Finished Installation

1. The images show the finished installation of both sides (Figs. F.1, F.2, F.3 & F.4). Finished installation images show the Load Lifter 5000 Ultimate Plus kit installed.

NOTE

INSTALLATION CHECKLIST

 Clearance test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and make sure there is at least 1/2″ (13mm) clearance from anything that might rub against each air spring. Be sure to check the tire, brakes, frame, shock absorbers and brake cables.
 Leak test before road test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and check all connections for leaks. All leaks must be eliminated before the vehicle is road tested.
 Heat test — Be sure there is sufficient clearance from heat sources, at least 6″ (152mm) for air springs and air lines. If a heat shield was included in the kit, install it.
 Fastener test — Recheck all bolts for proper torque.
 Road test — The vehicle should be road tested after the preceding tests. Inflate the air springs to recommended driving pressures. Drive the vehicle 10 miles (16km) and recheck for clearance, loose fasteners and air leaks.
 Operating instructions — If professionally installed, the installer should review the operating instructions with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.

Maintenance and Use Guidelines

1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI (7BAR).
3. If the system develops an air leak, use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring.

⚠ CAUTION FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS INDICATED BY THE VEHICLE MANUFACTURER.

⚠ CAUTION ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF 100 PSI (7BAR), THE AIR PRESSURE ACTUALLY NEEDED IS DEPENDENT ON LOAD AND GROSS VEHICLE WEIGHT RATING.

References

• SOM - State of Michigan

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