STEMCO Aeris Installation Manual
Contents
1. T Check Tire Pressure Regulator a 38 Troubleshooting COn ONBO G ainis a Page 3 of 41 MS ACRIisS S T E M C O Aeris Installation and Service M anual General Information About This M anual This manual is provided to support the STEM CO Aeris tire inflation system The manual provides the following information needed to install service and troubleshoot the Aeris system Explanation of Signal Words Please pay attention to special symbols used through this manual to convey important information Hazard signal words such as DANGER WARNING CAUTION or NOTICE are used throughout this manual Information accented by these words indicates a point of emphasis and importance The following definitions comply with ANSI 2535 4 and indicate the use of signal words as they appear within this manual DANGER Indicates immediate hazards which will result in severe personal injury or death WARNING Indicates hazards or unsafe practices which could results in severe personal injury or death CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates hazards or unsafe practices which could result in damage to machine or equipment IMPORTANT An operating procedure practice or condition that is essential to emphasize Safety alert symbol used to indicate a condition exists that may re2. 6157185300 Ms ACRIisS S T E M C O Aeris Installation and Service M anual STEM CO Aeris Installation M anual Part Number 01 571 8300 Revision 12 4 12 Rev B Aeris by STEM CO an advanced automatic tire inflation system based on patented rotary sealing technology and precision electronic airflow detection The system is designed to keep commercial trailer tires properly inflated using air pressure from the trailer s air system The rotary seal in an automatictire inflation system is a critical component it prevents the higher pressures needed to inflate commercial tires typically 100 psi from leaking into the wheel end which can handle no more than 6 psi Excess pressure can cause the wheel end seal to fail prematurely causing lubricants to exit the hub thus leaving moving parts susceptible to wear and seizure a dangerous scenario The rotary seal employed in Aeris by STEM CO differs dramatically from currently available systems and is targeted to increase the reliability and durability of these components substantially In addition to the high reliability and durability of the patented sealing system Aeris by STEM CO also includes several one way pressure relief valves per axle to ensure that the wheel end is never pressurized Aeris by STEM CO also includes a high resolution electronic flow detection technology capable of informing the driver whether the system is making a minor adjustment to tire pressure or if a ma
3. WARNING To prevent serious eye injury always wear approved safety glasses when performing trailer maintenance and service Page 8 of 41 Ms CRIS S T E MCO Aeris Installation and Service M anual e Park trailer on level surface e Set trailer parking brake e Chock each trailer wheel e Place jack stands under trailer e Bleed braking system of compressed air Axle Preparation Drain Oil e Place drain pan under hubcap for oil e Remove bolts from all hubcaps and allow oil to drain from each wheel end Drain Pan mar Part 102 5001 Drain oil into pan from each wheel Page 9 of 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual Welch Plug Removal e Remove welch plugs Drill a small hole off center in welch plug Hole should be smaller than plug removal spear on the end of slide hammer Using a slide hammer fitted with a welch plug removal spear to remove the welch plug Be careful not to score the inside diameter of the spindle bore e fyoudo not have a slide hammer you may be able to remove the welch plug by using a chisel and hitting the welch plug off center This should cause the plug to start turning inside the spindle unless there is a shoulder behind the welch plug Once the plug has turned enough to grab it with a pair of pliers and pull until plug comes out e lf plug cannot be removed drill a 1 2 hole in the welch plug Make sure as you are drilling the hole you don t s
4. FITINGS 1 DRILL PILOT HOLE 5 16 2 DRILL 7 16 v TOP WALL ONLY 3 TAP HOLES USING 1 4 18 NPT Note n Aneel Before drilling any holes in axle make sure they will C Clamp not interfere with any suspension components or brake components Contact STEMCO for technical assistance at 903 758 9981 in U S A Figure 5 Drilling Fixture Page 12 of 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual SAFHolnd 1 SeeFigre8 SeeFigme8 XN 0 0000000000000 See Figure 7 See Figure 7 Trax Pro 50 See Figure 9 See Figure 9 Mentr oo See Figure 7 See Figure 7 Holes Drilled in Windows Axle Wrap Approved drilling area 1 2 minimum from window edge Vent Hole Do Not Drill in This Area Figure 6 All holes will be drilled and tapped off center line of axle facing 45 degress forward Figure 8 Page 13 of 41 Ms WH R9 Aeris Installation and Service M anual Dnll amp Tap for 1 4 18 NPT ET a cem S l IE E 3 EJ m 10 0 L 10 0 E Inlet hole must be 1 5 away from the Chamber Braket Weld location Figure 9 Component Installation Instructions Wheels on each wheel end dual tires must have the valve stems clocked approximately 180 apart for installation of airlines to Aeris hubcap and valve stems on tires Clocking should be done prior to installing Aeris system See Figure 10 Clocking Wheels Clocking dual wheels is imp
5. Tractor Air supply hooked to air tank coming from the tractor compressor Aeris Hubcap Axle Air lines Air line from Aeris hubcap axle air lines hooked to Outlet on control box 1 4 Airline Tee Fittings 1 4 tube tee air line fittings to hook air lines from axles to air tank Control Box Air lines and electrical wiring run to control box for Aeris system Mini Ball Valve Air shut on off valve Must be in Open position for Aeris system to work Page 27 of 41 MS ACRIisS S T E M C O Aeris Installation and Service M anual Tire Hose Installation e Attach air hoses to the hubcap and the inner and outer valve stems The hose with the 180 fitting attaches to the outer valve stem Turn the valve stem swivel nut on the fitting until the rubber gasket just makes contact with the valve stem then turn the nut 1 2 turn more to ensure proper sealing Now push the hubcap end of the hose into the brass hose adapter fitting and turn the nut until the fitting is snug For final tightening turn the check port stem and the nut at the same time using only your fingers Do not use any type of valve stem extensions See Figure 24 and 26 e If installing on Super Single wheel only one hose is required See Figure 25 HOSE ADAPTER FITTINGSZ SINGLE HOSE Wide base single tire hose to hubcap connection Figure 24 Figure 25 Dual tire hose to hubcap connection IMPORTANT Make sure the hose s are not touching the tire rim Contact between the hose a
6. practices when installing General Service Installation Notes Work must be performed by trained personnel Use all recommended tools required to help avoid personal injury and damage to components Be aware of potential power release of tensioned springs on brake chamber or the brake return springs The release of tension can cause injury After installation perform operational checks and test the trailer to make sure the brakes are functioning properly before releasing back into service System Overview Page 5 of 41 Ms WHe 19 S T E M C O Aeris Installation and Service M anual e The Aeris tire inflation system is designed to automatically inflate tires that are below the target pressure setting The system uses air from the trailer s compressed air tank The compressed air tank pressure setting must be higher than the targeted tire pressure setting Failure to have the air tank pressure above the target tire pressure prevents proper operation of the inflation system System Features e Tire pressure is continuously monitored and adjusted automatically to the target tire pressure e Adjustable air pressure regulator is used for setting desired tire pressure target e An indicator light will illuminate when air is flowing to the tires e Does not pressurize axle tube prevent contamination of seals e Rotary seal air leakage will not enter the wheel end preventing oil contamination on the hubcap e Each wheel end has
7. 2 and Ground continuity to the circuit board and 7 pin connector e After power up works successfully take off the power lead and the light lead and connect them together the light should light up Page 40 of 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual If no then the connection to the light yellow line is not connected or the light is not grounded e fboth light and board power up then connect all wires back to the circuit board and verify that system powers up and blinks three times on a power up event both on the circuit board and at the front light on the trailer If the lights on the circuit board blink but the light on the trailer does not then you have a circuit board problem e If both the light on the trailer and the light on the board blink 3 times next check that the blinking stops or that the light on the front of the trailer goes to a solid on state or consistent blink state or an off state Those are all three valid states If the light on the trailer keeps blinking but in an inconsistent manner like two fast then one slow this means that pressure has not reached the control box yet Check that the air control valve is in the on position If the control valve is in the on position then the brake system has not received enough air to open the PPV valve yet Wait for the airbrake tank to fill or check glad hands are connected to the tractor e lf the light stays on solid or blinks consistently in timi
8. HUBCAP TO FITTING OF CENTER VENT LINE Figure 13 Axle Plug Installation Install the axle plug using the axle plug installation tool The tubing passes through the center of the axle plug which is then inserted into the hole on the installation tool Align the axle plug with the axle spindle and push leading edge of axle plug into spindle bore Now place the face of the installation tool against the axle plug and using a hammer gently hit the handle of the installation tool and seat the axle plug flush with the end of the spindle end Be careful to drive the axle plug in as straight and even as possible to keep plug from being cocked in bore Repeat this step on remaining axle wheel ends Small amount of wheel end lubricant can be applied to the rubber to help aid in installing axle plug Using a tubing cutter squares the end of the air line coming out of the axle after removing the masking tape Leave 5 6 of tubing sticking out of the spindle for easier installation of the Aeris hubcap See Figure 14 Page 18 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual METAL END AXLE PLUG r AXLE PLUG AXLE PLUG INSTALLATION TOOL TUBING THROUGH SLOT OF INSTALLATION TOOL Figure 14 Aeris Hubcap Assembly Installation e Place the hubcap gasket over the tubing before inserting it into push lock fitting on hubcap If you are installing a grease application hubcap make sure to follow recommended man
9. R INSIDE COVER Figure 35 Page 37 of 41 Ms WHSe l9 Aeris Installation and Service M anual System Installation Check e After the Aeris system is completely installed but before the trailer is put back into service all air system connections need to be checked for leaks Apply a soapy water solution to all air connections If bubbles appear at any fitting or air connection repair the connection Follow Instructions Below e Make sure the petcock valve on the trailer air tank is closed Fill the trailer air system and set all tire pressures just below the target pressures e Ensure the mini ball valve on the controller box is in the open position e Verify the trailer is connected to 12 volt power source e Verify the Red light on the circuit board in the control box is blinking If after applying 12 volts you don t see the light blinking disconnect the 12 volt power source and check all wire terminal connections and connections to the 7 pin connector box correct e Indicator light on trailer should come on and blink 3 times If insufficient pressure exists in the system the light will blink in a pattern of 1 long and then 2 short blinks if low flow exists the light will stay on constantly and if high flow exists the light will blink constantly e Ifthe indicator light remains on and the system continues attempting to inflate one or more tires to the proper pressure but can t due to the inability to maintain adequat
10. T E M C O Aeris Installation and Service M anual CONTROL MOUNTING BOX BRACKET AIR SUPPLY FILTER OUTLET AIR SUPPLY AIR SUPPLY VALVE AIR LINE FROM AXLES PRESSURE PROTECTION WIRECABLE PNE GLAND PETCOCK VALVE Figure 22 Air Lines to Compressed Air Tank IMPORTANT Open petcock valve on compressed air tank to release air pressure from tank Once compressed air is drained from the tank close the petcock valve e Remove large 3 8 Plug from side of compressed air tank e Install the 3 8 NPT M x 1 4 NPT F bushing e Install the 1 4 nipple e Install Inlet side of the Pressure Protection Valve on nipple e Install the 90 swivel elbow 1 4 NPT M X 1 4 tube DOT fitting to outlet side of PPV e Run a piece of 1 4 tubing from the 90 swivel elbow to the Inlet side of the control box fitting e Make sure the mini ball valve on the inlet side of the control box is in the open position See Figure 23 Page 26 of 41 f pep Ius pus MS ACRIisS S T E M C O Aeris Installation and Service M anual FRONT OF TRAILER 9 1 t 1 6 Figure 23 Item Description Air tank Trailer Air Tank Outlet Air Supply of Control Box Attach air lines from Aeris hubcap to Outlet side of control box Inlet Air Supply of Control Box Attach air lines from PPV to Inlet side of control box Pressure Protection Valve Required 70 psi minimum closing pressure Air Supply From
11. be made by using the actual fitting that will be inserted into the hole Using only hand applied torque the fitting should screw into the hole so that 2 to 3 threads are inside the hole before it becomes too tight to turn This is a trial and error process to get the right depth so use caution to prevent over tapping Once the tap depth is verified mark that depth on the tap wrap tape around it or mark with permanent ink so the tap can be driven to that depth on future holes When finished drilling holes use a cleaning wand connected to high pressure air to blow out shavings from inside of the axle Use safety glasses WARNING The use of a drill fixture is recommended Drilling free hand can create oblong holes Drilling should be done at a drill speed 7 16 drill 262 rpm to 786 rpm or drill speed 5 16 drill 367 rpm to 1100 rpm Keep drill straight when boring holes Tapping should be done by hand only Do not use a drill for tapping The use of a drill to tap holes can lead to threads being too deep or breaking the tap WARNING When drilling the 7 16 hole be careful as the drill bit breaks through the inside of the axle The drill bit can hang up causing the drill to twist in your hands When breaking through the inside of the axle apply less pressure and drill at a slower speed DRILL amp TAP AIRLINE HOLES BASED ON CHART BELOW HOLES ARE BASED ON MANUFACTURERS RECOMENDATIONS CENTER OF AXLE ec 3 HOLES IN AXLE FOR AIR
12. core the inside diameter of the spindle bore e Insert along steel rod into the 1 2 hole until it hits the back side of the welch plug in the opposite spindle Steel rod must be longer than the length of the axle Use a hammer to hit the rod and knock the welch plug out Pull rod out and repeat procedure on the plug with hole with the 1 2 hole in it Repeat procedure for second axle See Figure 2 DRILL HOLE FOR REMOVING WELCH PLUG OFF CENTER THIS WILL HELP IN PULLING WELCH PLUG ff w N gt i DRILL HOLE FOR SLIDE HAMMER Drill hole off center for slide hammer or rod Rod running through axle to other welch plug Figure 2 e Inspect the spindle bore for burrs Remove any burrs using straight die grinder with light grade flapper sanding wheel Clean the bore of any grinding debris e Check inside spindle to verify that the axle is hollow which is required for air line passage e Cover bearings and axle nut with clean towel to prevent contamination Page 10 of 41 Ms WH R9 S T E M C O Aeris Installation and Service M anual Drill Fixture Suggested Ox TPS xe STEEL PLATE WELDED ON 25r p 910 56 18 UNC F 630 Drill fixture for aligning holes on axle Drill bushing lock screw Drill bushings Type SF 3 Sizes 5 16 7 16 and 9 16 Figure 3 Figure 4 Drill fixture Determine Axle Requirements e Axle with nothing installed Start at Drill and Tap Holes e Axles with pre dri
13. dondadd Ev CFR C CF EFC P System OVERVIEW raisin eani EON ACERO ERA ER ECHO D UNE UAE E RT T UTC IN ROIS OVE VIEW MP a eii ral rubr Q Aeris Specifications System Operation How System Works System Components Recommended Tool Te Aens INStallavlOn wii allele hePal at O TET A AX Pre al a0 insiniiniii a A E EE ODOREM Drain Oil Remove Welch piiga E MP Drill Fixture How to M ake and Use M E TEE EIL Drill amp Tap Holes in SRM Clocking Wheels Pe TETTE reer tr errr cri rte error i Axle Hose installations Bid MeO Split Loom Tubing Protection Installation ee rT rr errr cere D Center Vent Line Installation DRM Axle Plug Installation Vs M LO Aeris Hubcap Assembly Installation S OnTor BOID TA O siii owd d a CELER DUCERE CA ERIT EY HE UE FEWER KR EE cer 22 Connecting Arnes 10 CONT BOXiasemva siano eno bM RED PE OE ED E 23 Air Lines to Compressed Alr Tal Kennen ofr o REC FR dO Mied SAE E a ak T AQEM VEU et DU RTL RE E A EVER NERE EXR EDD AUN 28 ORE Ead V IER TESES TREE Pleni Nb ia S Mss ere a NEG OO 5 X g9 CO gg 1 1 13 cO OY 010A S RR BE System Installation CII8CIGsnimisenn meo EDU GN ROD VERON EBENEN OHATRTOH ERE ECHO CA T OE S E E 0 t nanamn Maintenance
14. dual venting paths to prevent wheel end pressurization e Checks tire pressure constantly e Integrated check valves in the hoses isolate tires from system if a tire is damaged or leaking e ire pressure check ports are integrated into each hose eliminating the need to remove the hose to check the tire pressure e Anair filter is provided on the inlet air line to prevent particulates from clogging the system Aeris Specifications e Tire pressure setting range 70 120 psi e Pressure check interval Continuously supplies air to tires e System power requirements at 12VDC 12W e Minimum power voltage requirement to operate 9 VDC e Indicator light current range 50 mA to 600 mA e Tire inflation capacity per tire 10 psi in 2 3 minutes e The indicator light provides the following system information e No light System is good e Power up Light blinks three times e No pressure Long flash followed by 2 blinks repeating e Low volume flow Constantly on e High volume flow Blinking constantly Page 6 of 41 MS ACRIisS S T E M C O Aeris Installation and Service M anual System Operation How System Works The Aeris tire inflation system is designed to continuously supply filtered regulated compressed air to each tire on thetrailer There is no operation required of the driver for the system to function normally The only requirement of the driver isto verify the indicator lamp is functioning and to monitor the system period
15. e opportunity Remaining tires are protected from pressure loss by check valves integrated into each tire hose System Components List Hubcaps Spindle plug driver and plugs Air lines and fittings Light indicator and electrical wiring Control box with regulator and filter Control box mounting bracket Flexible wiring conduit Hardware kit Page 7 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual Recommended Tool List e 1 2 Drill e Drill Speed Recommendations Drill Speed 7 16 drill 262 rpm to 786 rom Drill Speed 5 16 drill 367 rpm to 1100 rpm Drill Bushings Type SF 5 16 7 16 and 9 16 Drill Bits 5 16 and 7 16 A variable speed 1 2 drive electric drill is recommended 1 4 18 NPT Tap L1 NPT Plug Gauge M edium to Heavy Duty Extension Cord Wire Strippers Wire Crimper Combination Wrenches 1 2 9 16 and 11 16 Hammer Drill Fixture See page 12 Ratchet and Sockets 1 2 9 16 and 11 16 2 Phillips Screwdriver Bit for Drill Cutting and Tapping Fluid 10 Agjustable Wrench Crescent Aeris Installation Trailer Preparation WARNING Before starting any work on trailer park trailer on a level surface Chock all wheels in front and back of each wheel to prevent the trailer from moving Support the trailer with safety jack stands Do not work under vehicle supported by jack stands only Jacks can slip and fall over Serious personal injury or damage to components can result See Figure 1
16. e pressure the system has a leak and must be repaired e Verify the oil level in each wheel end is at the correct level Maintenance Check Tire Pressure e Although the Aeris tire inflation system is designed to detect and fill a tire that s leaking during vehicle operation STEM CO recommends you inspect the tires for normal wear and damage at regular intervals and check the tire pressure as follows e Remove the metal cap from the check port that is provided on each hose See Figure 36 Page 38 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual Check Port Figure 36 Check pressure going to each tire using a pressure gauge e Ifthe tire pressure is lower than expected Replace fill cap and hand tighten e Ifthe tire pressure is lower than expected e Verify that the shut off valve is in open position e Check all air connections with soapy water solution If bubbles can be seen tighten fittings and check again with soapy water solution e f pressure is too high release some pressure from the tire dropping the tire pressure below the desired target pressure e The Aeris system will automatically inflate the tire to correct setting e Each tire should be checked for correct air pressure a minimum of once every 3 months Regulator Setting It s recommended that you check the regulator pressure once every 3 months to verify the regulator is still set at the desired pressure setting To set the regulat
17. flat washer on the outside of the box The box must be removed from the bracket before welding and the welded area must have some anti corrosion treatment such as cold zinc paint ADDITIONAL Pa x CROSS MEMBER BEAM MOUNTING OPTION f METAL BONDED ate SEALING WASHER a C CONTROL BOX GIL m 1 Hh j ry de 0p 8 Li n M NF H A EA Au ai 5 16 18 NYLON 5 16 FLAT WASHER LOCKING NUT BOLTING CONTROL BOX TO CROSS MEMBER 9 16 18 X 1 00 BOLTS MOUNT CONTROL BOX TO CROSS MEMBER BEAM USING TOP OR BACK PLATE HOLES Figure 19 Connecting air lines to control box e After the hubcap is tightened down push the rubber grommet on the air line down against the body of the fitting and tighten the nut Take the tubing from each spindle end and insert it into the air line tee fitting over the center of the axle It may be necessary to trim off excess tubing going to the center of the axle Repeat this step on all axles Page 23 of 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual Insert end of tubing into tee fitting on rear axle and run tubing to the front axle tee fitting and insert into front axle tee fitting M ake sure to leave enough airline tubing from rear axle to the front axle for axles that move Independent of each other to distribute load weight Use tie wraps to attach tubing to stationary areas to keep tubing from dragging or getting hooked on anything while t
18. he cable from the indicator light into the electrical box See Figure 34 e Remove the cover to the trailer 7 pin connector box See Figure 33 Page 34 of 41 Ms WHe 19 S T E M C O Aeris Installation and Service M anual Route the wire from the light into the 7 pin connector box Route enough wire into the box to have about 8 of wire sticking out and cut off excess wire Strip about 5 of the wire jacket from the wire using a jacket stripping tool M ake sure not to cut jacket so deep you cut into the insulation on the wires Strip off 1 4 of insulation from the black and white wire Route end of the 3 conductor wire into the 7 pin connector box Strip the wire jacket from around the wires back about 6 using a jacket stripping tool M ake sure not to cut jacket so deep you cut into the insulation on the wires Next strip 1 4 of insulation from the white brown and yellow wires Crimp a ring terminal on the end of the white wire from the light and crimp a ring terminal on the white wire going to the control box Both white wires coming to the 7 pin connector box should have a ring terminal crimped to them Use a terminal crimping tool Crimp ring terminal to the brown wire Crimp butt splice to the black wire from the light and the yellow wire from the 3 wire cable going to the control box Remove the nut from Pin 1 biggest pin on the 7 pin connector terminal and place both the white wires from the 3 wire cable andthe light
19. ically The Aeris system is preset to maintain a specific tire pressure in each tire The pressure in the trailer s air tank must be maintained above the targeted pressure to allow the controller to continuously supply and maintain the preset tire pressure to all tires IM PORTANT For Aeris controller to operate properly the air tank pressure must be greater than the tire pressure target The controller cannot supply tire pressure above the air tank pressure When the system is operating properly the air tank will supply pressurized air to the Aeris controller The controller will supply regulated compressed air to the air lines going to each tire If a tire is low air from the trailer air tank will inflate the tire until the targeted tire pressure is achieved Regulated air flowing from the controller to the air lines and tires may cause the indicator light to remain on until the target pressure is reached Constant pressure remains and is maintained in air lines and tires at the targeted pressure If a tire is leaking or there is a leak in the lines the indicator light may illuminate and stay on If the indicator light stays on for more than 10 minutes the system is attempting to inflate the tire or trying to correct for the air line loss to the targeted air pressure If this happens the operator should stop and check the tires manually to determine if it s safe to continue to operate the vehicle Operator should seek service at the next availabl
20. ide box if trailer is backed into loading dock that may be holding water See Figure 18 19 TOP MOUNTING HOLES 1 CLEARANCE HOLES FOR CONTROL BOX POST 2 MOUNTING HOLES FOR CONTROL BOX TO BRACKET 3 MOUNTING HOLES FOR BRACKET TO TRAILER CROSS BEAM TOP OR BACK HOLES MAKE SURE TO LEAVE ROOM FOR CLEARANCE OF HARDWARE WHEREVER BRACKET IS MOUNTED IF MOUNTING FLUSH AGAINST USING THE BACK HOLES OF BRACKET IT WILL BE NECESSARY TO DRILL HOLES THROUGH CROSS MEMBER FOR STUD WASHER AND NUT ON BACK OF MOUNTING BRACKET WHEN CONTROL BOX IS MOUNTED TO MOUNTING BRACKET Figure 18 Page 22 of 41 Ms WHe 19 S T E M C O Aeris Installation and Service M anual The control box has several mounting options In all mounting options the 5 16 sealing washer lock nuts and flat washers must be used The sealing washer is always on the inside of the box 1 Attach the box without the bracket directly to a cross member or frame section using the three 5 16 mounting holes in the bottom of the box Be sure to leave room at the top for the door to open up 2 Usethe mounting bracket provided with the Aeris system The bracket can be mounted using the holes on the side of the bracket or the holes in the top flange The control box can then be bolted to either side of the bracket holes are symmetrical 3 The mounting bracket can be welded to the trailer if desired but the frame must have clearance holes of the 5 16 mounting hardware nut and
21. itten permission Page 4 of 41 Ms WHe 19 S T E M C O Aeris Installation and Service M anual WARNING Always wear proper PPE when installing and performing maintenance repair servicing equipment or cleaning tractor or trailer components WARNING Solvent cleaners can be flammable poisonous and can burns or serious injury To help avoid serious personal injury carefully follow the manufacturer s product instructions and guidelines Please follow the procedures below Wear proper eye protection Wear proper protective clothing to protect your skin Always work in well ventilated area Do NOT use gasoline or solvents that contain gasoline Gasoline can explode and cause serious personal injury or death Hot tank solutions or alkaline solutions must be used correctly Follow the manufacturer s product instructions and guidelines WARNING Avoid creating dust from brakes when cleaning around any brake components Dust from brake pads and or parts are a possible cancer and lung disease hazard General Service Information Before starting any work or installation read understand and comply with the following Read all instructions and procedures Company s service maintenance installation and troubleshooting procedures Manufacturer s vehicle safety instructions when working on the vehicle Manufacturer s vehicle instructions not detailed in this service manual Follow all local safety regulations and best safety
22. jor leak is present An additional safety feature is a pressure protection valve to protect the integrity of the air brake system in the case of a major and continuous air leak such as a blow out or other catastrophic tire failure Aeris by STEM CO represents a leap forward in automatic tire inflation technology STEM CO starts with an unwavering commitment to increase the safety of our roadways by protecting the wheel end from damaging air Page lof 41 Ms CRIS S T E MCO Aeris Installation and Service M anual pressure and then added several additional safeguards and features Aeris augments our BatRF tire pressure monitoring systems to complete our suite of tire pressure management solutions 2 CE i MOOK yp CONTROL BOX AND INDICATOR LIGHT General View of Aeris Components Installed Refer to this installation guide on how to install the Aeris system on trailers Page 2 of 41 Mf rE Kis S T E M C O Aeris Installation and Service M anual Table of Contents General normato Nonainn FUCO COEM YU ERE UR ELO D CR RE HP LV E PR E DE HC P DEP E PR AOOUG IIS M ablildlwirt rr Ci R o REP V CD RAE GER CR FO D DM EE FE EE HEN ExDiaHatio nsi M COPS PIEDRA KG rcd FG FR n PEN DU E a p CERE HE a IMO Fant Sagre P NOHCOS niic EERONEAEE uo RE FP E Cr EE EDU CEDE CR D PC ER CH RE ER GelieralissrcednTokltia tO Doce EH ERE FRE ERU Dn PO KH EUROPE CODE RR DER General Service Installation NOLO usauiwiwk
23. l be attached to a tee fitting and then tie wrapped to the center axle vent line See Figure 13 Center Vent Line Installation e Install the push lock fitting 1 4 NPT x 3 8 tubing into the center tapped hole and tighten Insert the supplied 37 X 3 8 nylon tubing with the duck bill into the fitting The vent line should be oriented so the duck bill is pointing up and tie wrap it to frame or hoses of trailer where it s not going to be part of any moving component If this option is not possible the vent line can be routed around the axle Make sure the tubing goes around the axle 1 2 times Page 17 of 41 Ms ACRiIisS S T E M C O Aeris Installation and Service M anual Tie wrap and secure the end of the air line with the duck bill to the air line coming out of the axle M ake sure the duck bill vent is facing up and there aren t any big loops of air line hanging below the axle to snag on anything as trailer is moving Repeat this step on all axles where Aeris is being installed TIE WRAP AIR LINE T FITTING FROM HUBCAPS TO CENTER VENT LINE AFTER INSTALLED r LEAVE ABOUT 6 8 OF HOSE STICKING OUTFOR EASIER INSTALLATION AIR LINE TUBING TO eel N U T CUN SPLIT LOOM TUBING GROMMET FITTING BODY AIR LINE FROM HUBCAP TO CENTER OF AXLE IS CUT AFTER THE HUBCAP IS INSTALLED AND THE FITTING ON AXLE HAS BEEN TIGHTENED CUT HOSE LONG ENOUGH TO GO TO CENTER OF AXLE TIE WRAP CENTER VENT LINE AND AIR LINE FROM
24. le or straight edge of a structural cross member as cable is being routed through the trailer Use tie wraps to secure to existing airlines or electrical lines Page 31lof 41 MA CRIS S T E M C O Aeris Installation and Service M anual Figure 30 Page 32 of 41 Ms WHSe 19 S T E M C O Aeris Installation and Service M anual FLOW METER he ETT Light GROUND WHITE LIGHT CONTROL YELLOW POWER BROWN DRIVER WARNING LAMP BUTT SPLICE LIGHT CONTROL BLACK 1 PIN CONNECTOR ON FRONT OF TRAILER Figure 31 Once wire cable is pulled to the mounted controller box at the back of the trailer cut the cable M ake sure to leave enough wire to have about 12 of wire inside the control box Pull wire cable into the bottom of the control box through the cable gland Once wire is inside the box tighten the nut to seal up around the cable Tightening the cable gland will prevent water from entering the box and helps keep the cable from being pulled on which could lead to damaging the board inside the control box Next strip the wire jacket from around the 3 wires back about 4 using a jacket stripping tool Make sure not to cut insulation around 3 wires inside jacket Next strip 1 4 of insulation from the white brown and yellow wires Crimp the female wire disconnect spade terminals to the white brown and yellow wires using a crimping tool Now connect the yellow wire to the Light ter
25. lled holes but no hardware installed Start at Axle Hose Installation e Axle with Other tire inflation system remove airlines and fittings Start at Axle Hose Installation Drill and Tap Holes e Clean off axle for drilling holes for air fittings e Review the sketch of how drill fixture is made See Figure 3 amp 4 e Drill holes using the drill fixture Figure 4 to facilitate drilling and tapping of holes for the three air fittings Use a level to align the fixture and a c clamp to hold fixture in place figure 5 Use lubricant for drilling and tapping the holes e Use either an angle drill or standard drill where room permits With drill fixture is in place Figure 5 insert the 5 16 drill bushing in fixture and drill a pilot hole using a 5 16 drill bit Next insert the 7 16 bushing and drill the hole using a 7 16 drill bit Next insert the 9 16 bushing in fixture and using a 1 4 18 NPT tap the hole Repeat procedure on all 3 holes in each trailer axle IM PORTANT For some axle configurations you may be required to remove the slack adjuster and or the air brake chamber in order to access the drill locations specified by the axle manufacturer Page 11of41 Ms WHe 19 S T E M C O Aeris Installation and Service M anual Tap 18 NPT Proper tap depth determination for a tapered pipe thread NPT requires an L1 Plug Gauge which Stemco highly recommends If an L1 gauge is not available an approximation of tap depth can
26. minal on the board the brown wire to the Power terminal on the board and the white wire to the Ground terminal on the board Page 33 of 41 Ms CRIS S T E MCO Aeris Installation and Service M anual e Make sure to leave a loop at the bottom of the wires on the bottom of the control box This keeps water from running down the cable to the electrical board inside the control box See Figure 31 e Close box cover and snap lid clamps Depress the Schrader valve pin to discharge the pressure e Take the light and using the pigtail provided plug the square flat ends of the pigtail into the 2 holes on the back of the light M ake sure connectors snap in place fully e Now on the other end of the pigtail remove the 2 plugs in the ends of the connectors and plug in the wire extension Make sure connectors snap in place fully e Mount light in front corner of or side of trailer Mount light in location where driver can see it in driver s side view mirror e Mount indicator light to trailer using the self tapping screw provided Make sure to tuck wires inside back of light and where wires come out of slots provided to keep from pinching wire when mounted e Secure wire to trailer using p clamps M ake sure wiring is not hanging down to catch on anything IM PORTANT Make sure that as you are installing the p clamps you run the wire with a drip loop in the bottom of cable below the 7 pin connector box This keeps water from running down t
27. nd the rim could damage the rim IMPORTANT Make sure the tire hose s are not stretched so tightly that it puts a strain on the valve stem or the hubcap fittings Clock wheels if hoses are not aligned with the valve stems Page 28 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual OUTER VALVE STEM INNER VALVE STEM 180 FITTING INNER WHEEL SEE INSTRUCTIONS FOR PROPER TIGHTENING OF HOSE FITTINGS Figure 26 Light Kit and Wiring Installation e Once the control box is mounted and the air lines are connected to the controller the electrical wiring and light kit can be installed Improper wiring or operation of Aeris system can lead to the driver not being aware the tire inflation system is malfuncting e This section gives the basic instructions on wiring the Aeris system and routing the electrical wiring from the power source to the control box and light Hardware kit is shown below with items needed to install wiring and light See Figure 27 Page 29 of 41 Ms CRIs S T E MCO Aeris Installation and Service M anual Figure 27 Item Qty Description 1 1 Wire Extension for light Used to connect light to light and 7 pin power box 2 7 10X11 4 Self Tap screw Used to attach light and P clamps to trailer 3 5 P Clamps Used to clamp down wire from light to trailer and to 7 pin power box 4 3 Wire Ring Terminal Connectors for end of wires to 7 pin power box 5 3 Wire Female Disconnect Used t
28. ng then the system is taking air If no hissing is heard coming out of the air connections then the tires are low and simply taking air If hissing is coming from an air connection fixthe leak e Ifthe light goes out after the first 3 blinks then all is ok and tires are aired up WARRANTY INFORMATION All warranty returns may be sent to STEMCO 300 Industrial Blvd Longview TX 75691 Attn Warranty Dept Cc STEMCO A Higher Standard of Performance iustri Stemco USA Stemco Canada TS 16949 P O Box 1989 5650 Timberlea Blvd Unit B STEMCO BAT RF and AirBAT are all registered Longview TX 75606 1989 Mississauga ON L4W 4M6 trademarks of STEMCO LP 2012 P N 015718300 903 758 9981 1800 527 8492 905 206 9922 877 232 9111 FAX 1 800 874 4297 FAX 877 244 4555 WWW Stemco com Page 41 of 41
29. o connect white yellow and brown wire to Aeris controller box 6 1 Wire Butt Splice Used to connect light black wire to yellow wire from controller box 7 1 Light Pigtail Used to connect light to wire extension to 7 pin power box 8 1 Light Aeris signal indicator 9 1 Spacer Used for mounting lamp1 1 10 25 6 Tie wraps Used to secure wiring and airlines to trailer components e Runthe3 wire cable down through the front of the trailer in conduit or space provided by the trailer manufacturer M ake sure the cable stays inside the conduit or track between the tractor and the trailer Failure to do so may cause the wire to be damaged See Figure 30 e Make sure to route the 3 wire cable under the trailer through the same holes that the brake airlines and other electrical lines are running through M ake sure to secure the cable every 15 20 inches using the tie wraps provided Any excess cable that is not being used needs to be cut or bundled and tie wrapped to existing cable routings under the trailer See Figure 28 Page 30 of 41 Ms CRIs S T E MCO Aeris Installation and Service M anual IMPORTANT Make sure to run the 3 wire cable along the same path the airline from the brakes is routed This will insure that you have enough slack in the electrical line to keep it from be damaged by any moving parts on trailer See Figure 29 Figure 28 Figure 29 IM PORTANT Do not allow 3 wire cable to rub against a sharp edge of a ho
30. on the post Replace nut and tighten down Remove the nut from Pin 7 on the 7 pin connector and connect the brown wire from the 3 wire cable to the post This will be the center pin and will carry the power on systems that support ABS Page 35 of 41 Ms CRIS S T E MCO Aeris Installation and Service M anual F D Figure 33 e Next tuck all the wires inside the 7 pin terminal box and install the cover back on the box Make sure you don t trap any wires between the cover and the box that could cause the wire to short e Use tie wraps to attach 3 wire cable and wire cable from the light indicator to the airlines leading out of the 7 pin connector box See Figure 34 IMPORTANT Make sure you leave enough slack in the wires in the connector box to be able to remove the cover and work on the wiring without pulling any of the wiring lose from connectors when removing the cover of the box Page 36 of 41 Ms CRIs S T E M C O ae a 7 Aeris Installation and Service M anual _ TR ARAS 1 G PATENTS Dav ee TIME TR LER MFG CO v CFR Figure 34 Decal Location e Place decals on front of trailer by the indicator light and on the inside and outside of the control box cover See Figure 34 DECAL LOCATIONS FOR AERIS SYSTEM CONTROL BOX DIAGRAM PART NUBMER AERIS LOGO CONTRACT INFO ETC IP COMMUNICATION DRIVER WARNING AREA DECAL f ji FRONT OF TRAILER OUTSIDE FRONT COVE
31. or pressure follow the steps below e Open the cover to the control box e Remove the metal cap on the check port fitting on the regulator e Check the pressure with an accurate gauge such as a master gauge Page 39 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual e fthe pressure is correct replace metal cap and close the lid e fthe pressure is above or below the desired setting adjust the pressure using the adjustment knob See Figure 36 e fthepressureis low pull up on the regulator s knob to unlock Turn the knob clockwise to increase the pressure Allow the pressure to stabilize then check the pressure 2 3 times to verify correct pressure If the pressure is correct push the knob back down to lock in place and replace the metal cap e fthe pressure is high turn the knob counter clockwise to decrease the pressure Allow the system to stabilize and check the pressure 2 3 times to verify correct pressure Continue to decrease or increase the regulator until the desired pressure is achieved Pressure Adjustment Knob r gt jn LI DE P i T yee aT i T 63 Ti cl j f 2 l D 4 LJ in 2 i LJ Pressure Check Port Drip Loop p uid Figure 37 Troubleshooting AERIS Control Box installation debugging techniques e With the entire system connected apply power Does the red light on the circuit board blink at power up If no then check power connections 1
32. ortant Proper clocking allows the inner and outer valve stems to align with the hose attachment fittings on the Aeris hubcap Wheels with 2 hand holes can be clocked so the valve stems are exactly 180 apart but the valve stems on 5 hand holes cannot be clocked exactly 180 apart It may be necessary to remove the outer tire and rotate it to clock wheels properly Page 14 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual CLOCK INSIDE amp OUTSIDE INSIDE WHEEL VALVE STEMS VALVE STEM APPROXIMATELY 180 APART OUTSIDE WHEEL Figure 10 IM PORTANT Cut tubing with a tubing cutter approved for the use on DOT air tubing Knives pliers shears and other common tools can kink the tubing or not cut it squarely Poor executed tubing cuts can result in air leaks Page 15 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual 2 HAND HOLE WHEEL AIR LINE IN CENTER a OF HAND HOLE zw E HAND HOLE EDGE HAND HOLE EDGE Figure 11 e Dual wheels with 2 hand holes or aluminum wheels with small round valve stem clearance holes require a second alignment procedure to ensure the hoses will not touch the wheel To ensure perfect alignment between the hose attachment fittings on the hubcap and valve stems the wheels may need to be rotated one stud clockwise or counterclockwise See Figure 11 Axle Hose Installation WARNING Before pushing the air line tubing into the axle disassemble the pass th
33. riate levels for safe operation Allow oil levels to stabilize and add oil until at correct levels for each hubcap IMPORTANT Make sure oil levels in each hubcap are at the recommended levels for safe operation before using the trailer Fill and allow oil to settle then check oil levels again Add as needed to reach the recommended levels Control Box Installation e Install control box mounting bracket with hardware provided Mounting bracket can be mounted flush against the back of bracket flush against top of bracket to a cross member using top mounting holes or welded to the frame If welding weld the bracket to the frame before attaching the control box to the bracket Choose to best option for your application and a location that protects the control box from rocks debris etc as much as possible If trailer has a slider frame make sure bracket is mounted on cross member inside the slider frame box e Once mounting bracket is in place install the control box to the bracket using hardware provided e Mount the control box with the door facing the backend of the trailer if possible This will help protect it from road debris If this is not possible mount the control box in a location that allows access to the door but is as free from as many hazards as possible Do not mount control box near tires Control box should be mounted as high under the trailer as possible to keep debris from the road from hitting it and water from getting ins
34. rough fitting and place the components over the end of the air line in this order See Figure 12 e Pass Through Cap e Rubber O Ring e Pass Through Fitting Body e Now place a piece of masking tape over the end of the air line or plug the end of it so no debris can get inside the line as it is being pushed through the axle towards the wheel end Page 16 of 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual PASS THROUGH CAP RUBBER PASS THROUGH O RING FITTING BODY MASKING TAPE ROUTE TUBING TOWARDS SPINDLE END Figure 12 e Push the cap o ring and pass through fitting back approximately 5 in preparation for threading the airline though the axle e Route the air line through the axle towards the spindle end on each of the outer tapped holes until air line is protruding approximately 8 out of the spindle If air line hangs up inside the axle you may need to use something to help fish it through the spindle end M ake sure the air line doesn t have any kinks in it Split Loom Tubing Protection Installation e Place one of the supplied split loom tubing protection sleeves over the air line tubing of each spindle end to help protect against sharp edges inside the axle Repeat steps 1 4 on remaining axle wheel ends e The air line from the spindle end going to the fitting on the axle fitting can now be cut Make sure to cut the tubing long enough to reach just past the center of the axle The air line wil
35. ruck is moving On the front axle you will need to insert another tee fitting into the airline to connect the air supply to outlet side on the control box All airlines connected to the hubcap from each axle will be hooked up to the outlet side of the control box mounted under the trailer See Figure 20 21 and 22 Recommended to route and tie wrap airlines coming off the axles to existing wiring or tubing going towards the location where the control box is mounted making sure airlines won t be rubbing against any sharp edges that may damage airlines Center vent lines should be tied up under trailer so that duck bill vent is vertical and so that duck bill won t risk being under water if trailer is parked in a loading bay that may hold water Make sure to tie wrap center vent line to the trailer in an area that isn t a moving component which could risk it being pulled on Vent line may be wrapped around axle if needed just make sure duck bill is facing vertically and then tie wrap vent line to fitting coming of the axle to hold it in place CENTER VENT LINES TIED UP TO TRAILER DUCK BILL NEEDS TO BE POINTING UP Figure 20 Page 24 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual INSERTED TEE FITTING RECEIVES AIR SUPPLY FROM OUTLET ON CONTROL BOX INSERT TEE FITTINGS TIE WRAP FITTING TO CENTER VENT LINE ON BOTH AXLES REAR AXLE FITTINGS FRONT AXLE FITTINGS Figure 21 Page 25 of 41 Ms CRIS S
36. sult in personal injury or harm to individuals It must be applied to DANGER WARNING and CAUTION statements which emphasize severity IM PORTANT Please pay special attention to the information supplied in the Explanation of Signal Words section These words are used to help prevent immediate hazards unsafe practices severe personal injury or death and damage to machines or equipment Important Safety Notices Proper maintenance service and repair are important to the operation and reliability of the trailer suspension system and its components The procedures recommended by STEM CO as described in this manual are methods of performing maintenance inspection repair and service All warnings and cautions should be read carefully to help prevent personal injury and to help assure proper installation methods are used Improper maintenance service and repair can result in personal injury vehicle damage property damage unsafe operating conditions or void the manufacturer s warranty Carefully read understand and follow all safety related information in this manual WARNING DO NOT modify or rework parts Use only STEM CO Aeris authorized replacement parts Use of substitute modified or replacement parts not authorized by STEM CO may not meet STEM CO s specifications This may cause the part to fail which could result in loss of vehicle control and possible personal injury or property damage Do not modify parts without STEM CO s authorized wr
37. ufacturing guidelines for putting grease in bearings before you install the hubcap IM PORTANT Make sure grease is applied before installing grease hubcap if hubcap is a grease application e Install the tubing into the push lock fitting on the Aeris hubcap Push firmly on to ensure the tubing is fully seated Now push the hubcap and excess airline back into the axle spindle until the flange of the hubcap is flush with the hub Asthe tubing is being pushed back into the axle make sure it doesn t kink or bend e Align hubcap gasket with bolt holes on hubcap and install bolts Install all bolts and snug down until hubcap is seated against the hub When all bolts are snug use a torque wrench to finish tightening bolts to correct specification Tighten bolts using a star pattern as shown in figure 16 Torque bolts to 12 16 ft Ibs See Figure 15 and 17 Page 19 of 41 Ms CRIs S T E M C O Aeris Installation and Service M anual PUSH LOCK TUBING FITTING AERIS HUBCAP ASSEMBLY PUSH EXCESS TUBING BACK INTO AXLE WHEN BOLTING HUBCAP DOWN CUT AIR LINE GOING TO FITTING WITH TUBING CUTTER LEAVE 5 6 STICKING OUT PAST THE END OF THE SPINDLE PUT GASKET OVER TUBING THEN INSERT TUBING FIRMLY INTO FITTING ON HUBCAP MAKE SURE TUBING IS SEATED FULLY INTO FITTING PUSH EXCESS TUBING BACK INTO AXLE AND OUT OF THE AXLE TUBING FITTING BOLT DOWN HUBCAP TORQUE BOLTS 12 16 FT LBS Figure 15 Pull gently on the air line coming o
38. ut of the axle until you feel it get tight Now push the pass through fitting body down the air line and tighten it into the axle Next push the rubber o ring and the pass through cap down on the tubing to the fitting Before you tighten the pass through cap push 4 5 of air line back into the axle making sure not to kink the air line This will allow enough slack in the air line should you need to remove the Aeris hubcap later Tighten the pass through cap on the fitting Do not over tighten Using a tubing cutter cut air line coming out of the closed pass through fitting on the axle 5 past the center of the axle vent hole You want to make sure you have enough air line to attach to your tee fittings See Figure 16 Page 20 of 41 Ms CRIS S T E M C O Aeris Installation and Service M anual CENTER VENT LINE 5 0 PAST VENT LINE FROM WHEEL END Figure 16 e Repeat same procedures on remaining ends of all spindles M ake sure when feeding air line tubing into axle it heads towards the correct spindle end IM PORTANT Make sure to leave some slack in end of line when cutting for the hubcap airline fitting If hubcap needs to be removed you will need enough slack to unbolt the hubcap and be able to remove the airline from the air fitting Figure 17 Page 210f 41 Ms ACRIisS S T E M C O Aeris Installation and Service M anual e Depending on your hubcap type Remove plug on hubcap and fill with oil to approp
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