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Dunlop L.312.C.M, Installation Manual

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Dunlop L.312.C.M Installation Manual Download Page 7

L.312.C.M 

Mercedes-Benz Sprinter 200/300 

Volkswagen Crafter 28-35 

7 

DUNLOP and the Flying D Device are trademarks of Dunlop International Group and are used under license by DSC Nederland B.V.

 

www.dunlopsystems.nl 

4. COMPLETE ASSEMBLY 

The complete (left-side) auxiliary air suspension assembly is shown by 

the diagram below... 

1 Upper 

Bracket 

2  Load Sensing Valve Bracket 
3 Mounting 

Plate 

‘A’ 

4 Mounting 

Plate 

‘B’ 

5  Air Bellow (170mm Nominal Diameter, 2 Convolute) 
6  Lower Bracket Plate 
7 Lower 

Bracket 

Summary of Contents for L.312.C.M

Page 1: ... November 2018 Installation Manual DUNLOP and the Flying D Device are trademarks of Dunlop International Group and are used under license by DSC Nederland B V L 312 C M Mercedes Benz Sprinter 200 300 Series 1995 2006 Volkswagen LT 28 35 1995 2006 ...

Page 2: ...TALLATION 8 5 1 Bump Stop Removal and fitting of Upper Bracket Assembly 8 5 2 Fitting of Lower Bracket to Axle 9 5 3 Fitting of the Air Bellow 10 5 4 Fitting of Inflator Console 12 5 5 Tube Connection and Disconnection Cutting and Routing 13 5 6 Spring Inflation 14 5 7 Spring Alignment 15 5 8 Maintenance 15 6 EPILOGUE 16 CONTENTS 2017 DSC Nederland B V DSC Nederland B V Het Wegdam 22 7496 CA Henge...

Page 3: ...s are read thoroughly before commencing any installation work Installation should only be carried out by a suitably qualified mechanic or specialist installation facility DSC Nederland will not accept any responsibility for faults or defects arising from incorrect installation which automatically renders the guarantee invalid This kit is suitable for motorhomes and other vehicles with a minimum re...

Page 4: ...to rear and side to 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...

Page 5: ...ng load conditions This valve must be adjusted immediately after the fitting of an air assist kit and before the vehicle is driven again on public roads If the LSV is not adjusted following the fitting of an air assist kit it may misjudge rear load conditions to the extent that the braking pressure applied to the rear brakes is not correct e g the rear wheels may lock with no load on the rear axle...

Page 6: ...er license by DSC Nederland B V www dunlopsystems nl 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 pm85 pdf ...

Page 7: ... and are used under license by DSC Nederland B V www dunlopsystems nl 4 COMPLETE ASSEMBLY The complete left side auxiliary air suspension assembly is shown by the diagram below 1 Upper Bracket 2 Load Sensing Valve Bracket 3 Mounting Plate A 4 Mounting Plate B 5 Air Bellow 170mm Nominal Diameter 2 Convolute 6 Lower Bracket Plate 7 Lower Bracket ...

Page 8: ...cessary 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 5 1 Bump Stop Removal and fitting of Upper Bracket Assembly i Remove the bump stop If necessary use a long screwdriver or other implement to prize the stop free from its mount ii Offer the upper mounting plate assembly up to the bump stop ...

Page 9: ...he M8 holes are in alignment Attach the bracket to the plate using a M8x20 bolt and flat washer 5 2 Fitting of Lower Bracket to Axle i Place the lower bracket over the axle ensuring correct orientation as shown ii Mate the tongue on one end of the lower bracket plate with the slot in the lower bracket then swing the plate as shown until it contacts the flange on the lower plate with holes in align...

Page 10: ...and spring Simply push in the tube as far as it will travel and release see Section 5 4 Feed the other end of the tube through the large hole in the upper bracket ii Unscrew and disconnect the load sensing valve LSV linkage from the existing arm Unscrew the arm from the axle bracket and remove it iii Position the bellow between the chassis and the axle and attach the bottom plate of the bellow to ...

Page 11: ...stems nl iv Attach the top plate of the bellow to both the upper bracket and the load sensing valve bracket using two bolts and two flat washers Do not fully tighten at this stage because the bellow may require alignment once inflated see Section 5 7 v Attach the load sensing valve linkage to the bracket using a bolt two flat washers and a nut Complete and fully installed auxiliary air suspension ...

Page 12: ...fort 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 Option Valves Option 1 Option 2 Option 3 Your kit is supplied with one of the inflator options shown above O...

Page 13: ...icated 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 Recommended Electrician s Side Cutters NOT Recommended Connection and Disconnection Tubes are connected as shown by the diagrams below 5 5 Tube Connection and Disconnection Cutting and Routing A B C A Slide a nut over the end of the ...

Page 14: ... may impact the underside of the vehicle It is recommended that tubes are guided alongside brake lines as much as possible 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 and Minimum Pressure Maximum Pressure 7 0bar Minimum Pressure 0 5bar Do not exceed 7 0bar 101psi which is the reco...

Page 15: ... substance such as body wax The system does not require very much maintenance other than to maintain air pressure in the springs Much like a tyre the system may lose a little air over time 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 convolu...

Page 16: ...the fitting instructions 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 DSC Nederland by post fax or e mail Our e mail addres...

Page 17: ......

Page 18: ...ce are trademarks of Dunlop International Group and are used under license by DSC Nederland B V DSC Nederland B V Het Wegdam 22 7496 CA Hengevelde Nederland Tel 31 0 547 333065 Fax 31 0 547 333068 e mail info dunlopsystems nl Auxiliary Air Suspension ...

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