AIRBAG MAN Air Suspension Coil Helper Kit Land Cruiser 200 User Manual
- June 5, 2024
- AIRBAG MAN
Table of Contents
AIR SUSPENSION
COIL HELPER
Thank you for purchasing an Airbag Man air helper suspension kit. You have
purchased a quality product from Australia’s number one air suspension
specialist backed by the world’s leading airbag manufacturers.
This manual will provide answers to some of your questions regarding the use
and operation of your new air suspension kit. Following the guidelines in this
manual will help provide you with many years of trouble-free service.
WARNINGS & IMPORTANT INFORMATION
This Airbag Man air suspension system is designed as assistance to the
original vehicle manufacturer’s suspension – it is not meant to carry the
entire rated load.
It is recommended by Airbag Man that only a properly qualified person installs
the product and carries out maintenance.
If you are not qualified and attempt to carry out such work ensure that all
safety equipment is used and safety standards are met.
The safety of the vehicle and compliance with relevant State & Federal
regulations is the responsibility of the vehicle owner.
If your vehicle is fitted with a brake proportioning valve or stability
control system it is important to ensure this is maintained and adjusted
according to the vehicle manufacturer’s instructions.
Never exceed the manufacturer’s weight ratings for the overall vehicle (GVM)
or individual axles. Ensure you are fully conversant with how to position the
load on your vehicle.
A vehicle loaded in an improper manner can greatly affect safety & stability
and may result in twisting and stress on the chassis and overloading of axles
resulting in injury and/or vehicle damage.
When operating your air suspension ensure there is no one close to or under
the vehicle or they may be trapped and injured. Never drive with the air
suspension fully inflated and or with the vehicle raised over the
manufacturer’s suspension height. Read the operating instructions carefully
before using the system or driving the vehicle.
Never inflate an airbag assembly unrestricted. Improper use or over-inflation
may cause property damage or severe personal injury.
DOCUMENTATION TO BE KEPT WITH THE VEHICLE
It is very important that the vehicle owner or any driver is advised on how to
use the system and that this Product Manual and Fitting Instructions, showing
Specific Airbag Operating Pressures, provided with the kit is given to them
and kept with the vehicle.
WARNING STICKER
This is supplied with the kit and is required to be adhered to the vehicle
to notify any potential driver that it has an air suspension system fitted. It
is important that any driver is fully conversant with the system before
driving the vehicle.
https://airbagman.com.au/pages/search-part-
number
GENERAL OPERATING INSTRUCTIONS
HOW TO USE YOUR SUSPENSION
When you add or remove load to your vehicle the manufacturer’s suspension
height changes with the weight of the load. You are now able to maintain the
manufacturer’s suspension height front to back and side to side under these
differing load conditions (heights) by simply adding or removing air to and
from the airbags. Specific Airbag Operating Pressures can be found in the
Fitting Instruction document. Under load – return your vehicle to the
manufacturer’s suspension height by adding air to each airbag in turn. When
the load is removed – simply remove air from both the airbags to bring the
height down to the manufacturer’s suspension height. Use only enough air
pressure in the airbags to maintain the manufacturer’s suspension height. This
amount will vary depending on the load, location of the load & the condition
of the existing suspension.
It is not uncommon to have a pressure difference between the airbags after the vehicle has been brought to the manufacturer’s suspension height. If this is too great check inflation and redistribute your load more evenly.
Always maintain the manufacturer’s suspension height under all loads
Load the vehicle
within it’s legal payload
Inflate,
returning the vehicle to the manufacturer’s suspension height within the
Airbag MAXIMUM PRESSURE
SPECIFIC AIRBAG OPERATING PRESSURES
can be found in the Fitting Instruction document or via our website
The manufacturer’s suspension height relates to the primary suspension
components. Worn, damaged or mismatched suspension components are to be
addressed to ensure the correct height can be achieved and maintained across
the vehicle.
INFLATING & DEFLATING THE AIRBAGS
(See Specific Airbag Operating Pressures)
Before adjusting air pressure ensure no one is near or under the vehicle, as
they may become trapped or injured.
NEVER overinflate the airbags or damage may occur. (See Specific Airbag
Operating Pressures).
We highly recommend the addition of an onboard air control with our air
suspension products. If your vehicle is equipped with such a control system,
please refer to that device’s instructions. Otherwise for manual inflation:
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Locate where the airbag inflation valves have been situated on your vehicle. These are similar valves to those used to inflate your tires and therefore the same inflation tool will be ok to use. See opposite.
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With the airbags installed on your vehicle and the vehicle sitting on a level surface, verify that the vehicle is at the manufacturer’s suspension height. If required, the manufacturer’s suspension height can be achieved by inflating the airbags using an air source such as a standard tire inflator.
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Ensure the airbags are not inflated above the Maximum Pressure (See Specific Airbag Operating Pressures)
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Each airbag usually has a separate inflation valve.
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To maintain the manufacturer’s suspension height from front to back, add air pressure to both airbags in equal amounts gradually.
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To maintain the manufacturer’s suspension height from side to side, add more air pressure in small quantities, checking the pressure and height frequently.
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An airbag requires much less air volume than a tire and therefore will inflate/deflate much more quickly.
Never ride with the vehicle raised over the manufacturer’s suspension height.
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Inflate the airbags only enough to maintain the manufacturer’s suspension height, over-inflation to raise the vehicle above the manufacturer’s suspension height may result in unpredictable braking, handling, and/or become unstable, resulting in greater accident risk.
Never overload your vehicle or exceed the manufacturer’s weight ratings. -
Never exceed a manufacturer’s stated or Legal Gross Vehicle Mass or Axle Capacity (Weight Ratings). The manufacturer’s weight ratings are stated on the specification plate on the vehicle. You should weigh your vehicle on an authorized weighbridge when it is fully loaded at the manufacturer’s suspension height to determine if you are exceeding the manufacturer’s weight ratings.
Incorrect use of this air suspension product can result in damage to the airbag, associated parts, and/or the vehicle which is not covered under warranty.
Ensure the airbags are maintained at the manufacturer’s suspension height at all times and maintain the minimum pressure required and never exceed the maximum. (See Specific Airbag Operating Pressures)
An airbag operated below or above the manufacturer’s suspension height or over/under pressurized can result in airbag failure or vehicle damage. This is not covered under warranty.
Ensure you load your vehicle evenly and safely within manufacturers’ specifications.
MAINTENANCE
It is recommended that only a properly qualified person installs the product
and carries out maintenance.
Periodically inspect your air suspension for operation, security, possible
damage & component integrity.
As with your vehicle’s tires, an airbag is a pneumatic device that supports a
portion of the vehicle’s weight. The airbag may fail as a result of punctures,
impact damage, improper inflation, improper installation, or improper usage.
To reduce the risk of failure, we strongly recommend the following:
Never inflate an unrestrained airbag and fully deflate the airbags if:
It is necessary to lift the vehicle by the chassis. This will allow the airbag
to extend to its maximum length without being damaged.
If you are going to remove an airbag or other component from the suspension:
Whilst securely installed in the vehicle inspect the inflated airbags to
verify that they avoid contact with any other component on the vehicle under
all expected operating conditions and pressures. There must be at least 13mm
(1/2”) of clearance all around.
If an airbag has failed while you are traveling STOP in a safe manner and
place to effect a repair.
Readjust the air in the remaining airbag. You will now be operating on the
original suspension as the vehicle manufacturer intended until a repair can be
made. It is recommended to operate your vehicle at reduced speeds to avoid
further damage to your vehicle or suspension. In all cases, high speed over
rough roads may result in severe bottoming out of the airbags causing damage.
Never cut, weld, or modify the airbag or associated parts without approval
from Airbag Man.
Do not use aerosol tire repair products in airbags. If there is a hole the
airbag must be replaced.
Do not use a tire patch of any kind on an airbag. If there is a hole the
airbag must be replaced.
Never weld within sight of an unprotected airbag; they are severely affected
by weld UV & heat.
EXHAUST HEAT
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Inspect the airline tubing and the airbags to verify that they have not been damaged due to exposure to heat from the exhaust system. The standard kit design takes into consideration a standard exhaust and normal use.
Exhaust modifications from standard or incorrect fitment can cause eventual heat damage issues. -
Should you have the exhaust system modified this may result in increased heat exposure to the airbags, which may reduce the life span. Please contact Airbag Man before any exhaust modifications are carried out.
TORQUE SPECIFICATIONS
Use a torque wrench for tightening fixings and only tighten to the relevant
specification for the size and thread otherwise, damage may occur.
SELF LOCKING FASTENERS
The air suspension system may include a variety of self-locking threaded
fasteners. Prevailing-torque lock nuts may be more difficult to install or
remove, but will not come loose under normal suspension operation. Note that
Nylok™ type lock nuts may be used in this manner also, in place of the
prevailing- torque type, except where high heat is present.
Spring washers – In order to properly use a lock washer, tighten the nut/bolt
fastener following the torque recommendations above.
FITTINGS & TUBING
Your kit will include push-to-connect air fittings. Some fittings are able to
be swiveled to align the push-to-connect fitting to the airline. Additional
thread sealant is not normally needed, however, can be used if these fittings
are reused as this will degrade their nylon sealing ability.
Always ensure all air is removed from the system prior to attempting to remove
the airline, airbags and or fittings.
If you need to disconnect the airline:
- Removal – Push the collet towards the body of the fitting, and then hold in that position whilst pulling the airline out.
- Refit – Cut the airline as square as possible using a proper tube-cutter. Push the recut airline into the fitting as far as possible.
- If you use a sharp utility knife or razor blade great care must be taken in all cases not to cut yourself during this operation.
Any damage to the airline section that enters the fitting will cause a leak and must be trimmed to a clean, straight airline section.
ENSURE SCRATCH-FREE STRAIGHT AIRLINE FOR PUSH TO CONNECT FITTING SEAL
The Push To Connect fitting houses an o-ring and collet to seal and secure the
nylon airline. 
AIR LEAK CHECK
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It is normal for an airbag system to permeate the air and lose pressure over time. Please ensure the manufacturer’s suspension height is maintained and any excessive leaks are checked and repaired.
Note: pressure loss occurs each time it is checked. (See Specific Airbag Operating Pressures) -
If you encounter an air leak or have carried out repairs to the air system a leak check has to be performed.
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Inflate the airbags to the maximum allowed pressure and spray all components with a soapy water mix.
Ensure airbags are adjusted to the manufacturer’s suspension height after any test and before driving.
AFTER-SALES SERVICE
GENERAL ADVICE & ASSISTANCE
Airbag Man is proud to offer the best quality products and customer service.
If you have any issue with our product you must call us to discuss a solution
and local service if required.
Also, see the Troubleshooting Guide in this booklet for assistance before
calling.
SPARE PARTS
We carry an extensive range of spare parts and have knowledgeable service
dealers throughout the country. Should you require spare parts please locate
the kit part number found in the fitting instructions and call us for
assistance.
WARRANTY
Our Warranty operates in addition to (and does not exclude, restrict or
modify) any rights or remedies to which you may already be entitled under the
Australian Consumer Law or any other relevant law relating to this product.
Our Goods come with guarantees that cannot be excluded under the Australian
Consumer Law.
If the product supplied has not performed as expected and you suspect it may
fall into the consumer protection category please call 1800 247 224 for
assistance.
FOR SUSPECTED WARRANTY CLAIMS – PLEASE CONTACT THE AIRBAG MAN BEFORE REPAIRS ARE CARRIED OUT FOR ADVICE AND A CLAIM FORM MUST BE COMPLETED. FREECALL 1800 247 224
TROUBLESHOOTING GUIDE
The airbag will not inflate
Do you have a good air supply?
Make sure all connections are made.
Check for dirt in the valve core and correct operation of the valve. Check
that the inflation valve is mounted to leave enough thread depth for the
inflator to operate it. If mounted through material thicker than 5mm it may
not allow the valve to open. (Relocate) Inspect the entire length of tubing
to make sure tubing is not trapped, melted together or cut from rubbing on
sharp edges.
If you have an air supply system other than manual inflation refer to the
relevant document for information.
The airbag will not hold air
Air loss is expected each time the airbag pressure is checked.
Check to see if the valve core is tight. The inflation valve cap can be used
as a valve core tool.
If loss of air is excessive a solution of 25% soap and 75% water can be used
to inspect the airlines, fittings, and airbags. Look for air bubbles forming
in these areas and obvious leaks visually.
Finding a stubborn leak
With the airbags on the vehicle, inflate to the maximum allowed pressure then
start at one end of the airline and inspect for leaks. A solution of 25% soap
and 75% water can be used. Apply the soap solution to all air fittings, valve
core, and airbag. Rinse the solution from the system when complete. (See
Specific Airbag Operating Pressures)
Common location of air leaks
Air leaks are often due to damaged airline installed into the fitting which
must be repaired by re-trimming to a clean section of the airline. Leaks can
also occur in the attachment of the air fittings to the airbags due to the
fittings not being tight enough or sealed with thread sealant. Tighten the
fittings one more turn or remove and apply a suitable thread sealant.
Tubing must be cut squarely to avoid burrs in the connection to the air
fittings. Push-to-connect fittings require a square cut to assure a seal. With
air pressure removed the tubing can be easily removed by applying pressure to
the brass collar toward the fitting, the tubing can then be pulled free from
the fitting. To install the tubing, make sure that the tubing is cut squarely
and pushed into the fitting as far as possible.
The vehicle is not level
Check for proper inflation of the airbags on each side. Check for obstruction
or components that may be restricting the suspension.
Ensure the vehicle is adjusted to the manufacturer’s suspension height after
any test and before driving.
9 Hinkler Court
BRENDALE DC QLD 4500
AUSTRALIA| PO Box 5883
BRENDALE QLD 4500
AUSTRALIA| Ph 07 3889 6556
Fax 07 3889 6557
Int +61 7 3889 6556| info@airbagman.com.au
Visit our website at
airbagman.com.au
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