Blueair BBB90 - 4B Installation manual
Contents
1. rating of your vehicle This must be carried out by a specialist supplier that will e carry out any necessary modifications in addition to fitting the air assist kit e complete documentation as necessary to inform the Vehicle and Operator Services Agency VOSA a mandatory requirement e supply and fit a new weight plate to replace the original plate supplied with the vehicle This process applies to United Kingdom registered vehicles The process in other countries may be different Safety Guidance Note The following very useful guidance note is available for free download from the Health and Safety Executive HSE PM85 July 2007 Safe recovery and repair of buses and coaches fitted with air suspension The uniform resource locator URL for this document is http www hse gov uk PUBNS pm685 pdf DUNLOP SYSTEMS AND COMPONENTS 4 OVERVI EW The diagram below is an overview of the complete assembly POS ARTIKEL NUMBER DESCRIPTION AMOUNT OP LB 170 2 CPL 170 2 AIR BELLOW 65 05 00 1 01 UPPER BRACKET DISC SPRING WASHER 8 x 13 DIN 933 M8x16 HEXAGON BOLT M8 x 16 DIN 933 M8x25 HEXAGON BOLT M8 x 25 65 06 00 1 04 01 LOWER PLATE 65 06 00 1 04 02 FIXATION BRACKET LOWER PLATE DIN 7991 M8x12 M8 x 12 COUNTER SUNK BOLT DIN 125A M8 WASHER M8 10 DIN 985 M8 SELF LOCKING NUT M8 N CON DUI 45 Ww L2 I A A N NA The kit is also supplied with black and blue air hose and an inflation possibility See Se2. Auxiliary Air Suspension DUNLOP SYSTEMS AND COMPONENTS Installation Manual L MAS 10D C M RwD Single and Double tire Nissan NV400 2010 Onwards Opel Vauxhall Movano 2 2010 Onwards Renault Master X62 2010 Onwards August 2012 www dunlopsystems com DUNLOP SYSTEMS AND COMPONENTS CONTENTS l FOREWORD in 3 Ze INTRODUCTION senvi svenas ii turtur 4 3 VERY IMPORTANT NOTES rr 5 di OVERVIEW ani 6 5 INSTRUCTIONS FOR INSTALLATION eee 5 1 Recommended Tightening Torque s 7 5 2 Installation of the air suspension at the left side 8 5 3 Installation of the air suspension at the right side 8 5 4 Fitting of Inflator Consolare 9 5 5 Tube Connection and Disconnection Cutting and Routing 11 SPERI 12 Dik SPONDA 13 9 6 51544 13 Dili CACCE I gt ani ia 14 5 10 Installation DraWwinGS asia SEES KLE dr CR VEO 15 O EPIEOGUE Lele 16 Dunlop Systems and Components Dunlop Systems and Components Het Wegdam 22 Holbrook Lane 7496 CA Hengevelde Coventry CV6 4QX Nederland United Kingdom Tel 31 0 547 33 30 65 Tel 44 0 24 7629 3300 Fax 31 0 547 33 30 68 Fax 44 0 24 7629 3390 www dunlopsystems nl 2008 Dunlop Systems and Components DUNLOP SYSTEMS AND COMPONENTS 1 FOREWORD This manual provides instructions for the insta
3. ction 5 4 DUNLOP SYSTEMS AND COMPONENTS o EA 5 INSTRUCTIONS FOR INSTALLATION Preparation and Precaution Before beginning installation ensure that you have sufficient clearance between the axle and the chassis at least 25cm Use a Jack if necessary Install at one side of the vehicle at a time Pay attention to your safety at all times during installation always use axle stands to support the vehicle Start by jacking up the rear side till approximately driving level and measure the distance between the rear axle and the chassis at the location of the bump stop This should be app 14 cm If this is app 18 cm you will need a 3convolute air bellow 5 1 Recommended Tightening Torque During fitting of the air suspension system it is recommended that nuts and bolts are tightened in accordance with the following table METRIC TORQUE CHART in N m e When both the bolt and nut are made SIZE CLASS 8 8 CLASS 10 9 Aluminium from steel use either class 8 8 or 10 9 and PA6G 10 14 4 e For all other materials tightening torque is left to the discretion of a person skilled in the art DUNLOP SYSTEMS AND COMPONENTS AQA The following instructions make reference to the diagrams on pages 14 to 16 inclusive 5 2 Installation of the air suspension at left side 1 Remove the bump stop You can easily push the bump stop out of its holder The M10 bolt is to be reused for the mounting of t
4. he up per bracket Photo 1 7 2 Now there is space created to install the lower plate and air bellow 3 Attach the lower plate with two M8 x12 counter sunk bolts Photo 8 take care that the air nipple will be at the inside of the chassis 4 Liftthe rear side of the assembly a bit Photo 9 so you can easily shift the assembly from the inside on it s place Photo 10 11 5 The integrated clamps will keep the assembly on it s place they have to be in between the two ribs of the anti roll bar bracket Photo 12 6 The middle stop positions the plate Photo 12 7 Now install the little bracket at the other side of the lower plate with the two hexagon M8 x 25 bolts washers and nuts Photo 13 18 8 Also this little bracket has to be in between the two ribs of the anti roll bar bracket Photo 18 9 Install the upper bracket with it s original bolt Photo 6 19 amp 20 The hole to guide the air hose trough has to be on the inside 10 Remove the plug Photo 21 11 Guide the black air hose through the hole on the inside and connect it to the air bellow Photo 22 23 Caution Don t tighten the special nut of the air line not to tight See Section 5 5 12 Bring the air bellow into position on the rear axle and install both M8 bolt with disc washer finger tight at the top side see Photo 24 13 Before tightening all bolts and nuts definitely install the right side 5 3 Installation of the air suspension at the righ
5. llation of an auxiliary air suspension kit developed specifically for the Renault Master X62 Opel Vauxhall Movano 2 and Nissan NV400 2010 onwards rear wheel drive double tire and single tire To ensure correct installation of the kit it is strongly recommend that these instructions are read thoroughly before commencing any installation work Installation should only be carried out by a suitably qualified mechanic or specialist installation facility Dunlop Systems and Components will not accept any responsibility for faults or defects arising from incorrect installation which automatically renders the guarantee invalid I MPORTANT Manufacturer s Declaration Form A manufacturer s declaration form is provided with your kit Following installation of the kit please ensure that this form is completed and signed by a qualified fitter and that a copy is returned to Dunlop Systems and Components by post fax or e mail SYSTEMS AND COMPONENTS a 2 INTRODUCTI ON Thank you for choosing an auxiliary air suspension kit from the range offered by Dunlop Systems and Components Auxiliary air suspension is fitted in tandem with the standard steel springs of the vehicle suspension and provides enhancements in terms of both the stability of the vehicle and the comfort of the passengers Vehicle Levelling Simply by varying the air pressure in the springs the vehicle can be levelled both front to rear and side to
6. ns it is important to coat all the steel parts with a protective substance such as body wax IMPORTANT Manufacturer s Declaration Form A manufacturer s declaration form is provided with your kit Following installation of the kit please ensure that this form is completed signed by a qualified fitter and a copy is returned to Dunlop Systems and Components by fax post or e mail As a condition of your warranty modifications to the system may only be carried out by personnel of Dunlop Systems and Components or an appointed agent Enquiries For general enquiries please either telephone Dunlop Systems and Components Nederland 31 0 547 33 30 65 Dunlop Systems and Components UK 44 0 24 7629 3300 0r e mail info dunlopsystems nl or info dunlopsystems com Auxiliary Air Suspension DUNLOP Dunlop Systems and Components Het Wegdam 22 7496 CA Hengevelde Nederland Tel 31 0 547 33 30 65 Fax 31 0 547 33 30 68 SYSTEMS AND COMPONENTS Dunlop Systems and Components Holbrook Lane Coventry CV6 4QX United Kingdom www dunlopsystems com Tel 44 0 24 7629 3300 Fax 44 0 24 7629 3390
7. nt the console in a position of your choice whereby it is firmly fixed has some protection from the environment particularly important for the console with gauges and is easily accessible Suggested possible locations include Standard Console Option 1 Option 2 or Option 3 e onthe rear bumper Console e at the rear beside the license e in the vehicle cabin within reach plate and sight of the driver onthe chassis next to a rear e Beside under the driver seat wheel e in the wall of a cupboard e ina service shutter motorhomes motorhomes e ina service shutter e beside the fuel cap motorhomes Comfort Packages The Option 2 and Option 3 panels as shown above are each part of a Comfort Package that is supplied with a compressor and also an air reservoir in the case of the Option 3 panel for ease of spring inflation and ride height setting For further information please ask your dealer The photograph below shows all of the parts of Comfort Package Option 2 se Comfort Package Option 2 DUNLOP SYSTEMS AND COMPONENTS 5 5 Tube Connection and Disconnection Cutting and Routing Connection and Disconnection Tubes are connected as shown by the diagrams below A Slide a nut over the end of the tube B Push the tube onto the connector as far as possible C Feed the nut up to the connector fully tighten by hand and finally tighten one additional turn using
8. out use but a pressure of at least 0 5bar 7 25psi should be maintained at all times in order to avold possible compression damage to the springs Maximum and Minimum It is wise to hand over the vehicle 24 hours after the installation is done Just to assure the customer will leaf with an airtight system DUNLOP SYSTEMS AND COMPONENTS 5 7 Spring Alignment Om Spring out of alignment Spring in alignment mounting plate axes offset mounting plates parallel and coaxial AN CAUTI ON Before fully tightening the bolts that secure the air spring to the upper and lower brackets set the vehicle at ride helght spring height approximately 13 5cm and ensure that the springs are correctly aligned 5 8 Maintenance Following installation it is recommended that all metal parts are coated with a protective substance such as body wax The system does not require very much maintenance other than e to maintain air pressure in the springs Much like a tyre the system may lose a little air over time e to keep the air bellows clean It is suggested that when washing the vehicle the bellows are inspected and cleaned as necessary preferable by spraying Look in particular for stones or grit trapped between convolutes as this may damage the bellow e Check before and after the winter period the wax coating Re wax when necessarily DUNLOP SYSTEMS AND COMPONENTS 5 9 Check Lis
9. side Keeping the vehicle level optimises stability ensures correct headlamp beam distribution and reduces tyre wear arising from uneven distribution of weight Straight Line Stability Straight line stability is greatly increased at higher speeds and when subjected to buffeting from cross winds or large overtaking vehicles Reduced Body Roll Body roll when cornering or negotiating roundabouts is significantly reduced Fatigue Reduction and Wear Compensation Suspension fatigue is reduced so helping to prevent leaf springs from sagging under repeated or constant loading Any sagging already present can be compensated for This is a particular benefit for motorhomes which are always fully laden Ride Comfort Air springs help to absorb shock loads from uneven road surfaces therefore general ride quality is much improved DUNLOP SYSTEMS AND COMPONENTS D 3 VERY I MPORTANT NOTES Gross Vehicle Weight GVW A Air assist kits are not in themselves designed to increase the gross vehicle weight GVW rating of a vehicle They do not legally allow for carriage of a load greater than the carrying capacity stated on the data plate of the vehicle Do not exceed the maximum load specified by the vehicle manufacturer e to avoid compromising passenger safety e to prevent possible damage to the vehicle e for legal reasons Vehicle Uprating Despite the above words of caution it is possible to upgrade the weight
10. spanners Cutting To achieve good sealing and air tight fitting of tube ends to their connecting parts it is very important to cut tubing cleanly and squarely A dedicated guillotine action tubing cutter is recommended or a craft knife if such a tool is not available Do not use electrician s side cutters A dedicated tubing cutter Electrician s Side Cutters Recommended NOT Recommended DUNLOP SYSTEMS AND COMPONENTS AOA Routing Study the underside of the vehicle and decide how to route each branch of the air circuit e To minimise the risk of chafing avoid running tubing over metal edges as much as possible e Avoid close proximity to heat sources such as the exhaust assembly e Choose a route that provides as much protection as possible from dirt debris and any solid objects that may impact the underside of the vehicle It is recommended that tubes are guided alongside brake lines as much as possible Use cable ties tie wraps to secure tubing to the chassis taking care not to over tighten them 5 6 Spring Inflation Once installation of the air assist kit is complete inflate the springs via the inflator console taking careful note of the following Maximum Pressure 7 Obar Minimum Pressure 0 5bar Do not exceed 7 0bar 101psi which is the recommended maximum charge pressure for the air springs The springs may be deflated if the vehicle is to be stored for a lengthy period with
11. t Before driving the vehicle following completion of installation of the auxiliary air suspension system please check all bolts tightened to the recommended torque Page 8 air springs set in alignment Section 5 4 enough free space around the air springs to avoid wearing all metal parts wax coated Section 5 5 manufacturer s declaration form completed and a copy returned E ILILILILI Z N A wait of 24 hours is recommended in order to ensure that the IL vehicle has maintained its stance and that there are no air leaks present DUNLOP SYSTEMS AND COMPONENTS Nissan NV400 Opel Movano Renault Master L MAS 10D C M 5 10 Installation Drawings 15 www dunlopsystems com ATE EI E m gt Renault Master Opel Movano L MAS 10D NV400 issan N C M com dunlopsystems WWW 16 ZA c2 lb gt DUNZOF Nissan NV400 Opel Movano Renault Master L MAS 10D C M CT 17 www dunlopsystems com i1 gt DUNLOP Nissan NV400 Opel Movano Renault Master L MAS 10D C M 4 AQ E LN ni 18 www dunlopsystems com DUNLOP SYSTEMS AND COMPONENTS 6 EPI LOGUE Dunlop Systems and Components hopes that you enjoy the benefits that your air suspension system will provide for you To ensure optimal performance we advise that you have your system checked frequently by qualified personnel As recommended in the fitting instructio
12. t side 1 Item 1 till 12 are identical to the left side accept that the right side we use blue hose and of course Is the right side mirror wise 14 Bring the vehicle till driving height when the vehicle is almost totally empty you have to bring weight into the vehicle Driving height is app 13 5 cm of course can this height be modified a little on request of the Vehicle owner 15 Before tightening all bolts and nuts definitely See section 5 1 the alr bellow needs to be aligned See Section 5 7 16 Now you can guide the air hoses See Section 5 5 DUNLOP SYSTEMS AND COMPONENTS 5 4 Fitting of I nflator Console STANDARD OPTION 1 OPTION 2 Your kit is supplied with one of the inflator console options shown above STANDARD OPTION 1 OPTION 2 OPTION 3 Two valves and a small bracket Two valves in a console with two independent 10 bar pressure gauges Two valves in a console with two independent 10 bar pressure gauges and a rocker on off switch to operate the electric motor driven air compressor Four valves two for raising the vehicle UP and two for lowering the vehicle DOWN in a console with two independent 10 bar pressure gauges A pressure switch operates the electric motor driven air compressor to keep the air reservoir of 2 2 litre at pressure A special dashboard panel is available for OPTI ON 1 and OPTI ON 2 DUNLOP SYSTEMS AND COMPONENTS Mou
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