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MAINTENANCE & INSTALLATION
MANUAL
VDL Weweler bv Project: WAP12-039-009
Date: 01-05-2016 Document Nr.: WSM-MBSA-EN-Rev.I
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
1
CONTENTS
Page
1. INTRODUCTION 2
2. MAINTENANCE WORK 3
1. AIR SPRING VISUAL CHECK 4
2. SHOCK ABSORBERS 4
3. AXLE-CLAMP BOLTS 5
4. PIVOT BOLTS 5
5. AIR SPRINGS 5
6. BUMP STOPS 6
7. AXLE LIFT & SPLITTER 6
3. GENERAL INFORMATION 6
4. MBS AIR SUSPENSION SYSTEM INSTALLATION INSTRUCTIONS & GUIDELINES 7
1. Assembly of MBS trailing arm 7
2. Assembly to the trailer chassis 11
3. Paint instructions BEFORE mounting the air suspension with axle to the trailer chassis 12
4. Paint instructions AFTER mounting the air suspension with axle to the trailer chassis 15
APPENDIX A : WM-C18 18
APPENDIX B : WM-C15-GB 19
APPENDIX C : IM-141 20
APPENDIX D : WM-C20 21
APPENDIX E : IM-142 22
APPENDIX F : WM-C22 23
APPENDIX G : WM-C24 24
APPENDIX H : IM-145 25
THIS DOCUMENT IS SUBJECT TO CHANGE (WITHOUT NOTICE). NO RIGHTS CAN BE CLAIMED FROM THIS DOCUMENT. VDL WEWELER IS NOT RESPONSIBLE FOR ANY ERRORS, MISPRINTS OR OMISSIONS IN THIS PUBLICATION.
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
2
1. INTRODUCTION
The maintenance instructions in this manual covers VDL Weweler MBS air suspension systems.
It is essential to observe the maintenance intervals specified by the manufacturer, this will ensure
continuous operational safety and roadworthiness.
If the operator of the trailer does not have the required technical equipment and/or expertise is not
officially authorised to carry out intermediate inspections, contact VDL Weweler.
(see http://www.vdlweweler.nl)
They can supply detailed technical information and the correct procedure for replacing worn parts.
Ensure that when fitting replacement components, only fit VDL Weweler genuine parts. This will
avoid invalidating warranties, type approvals, local and international regulations.
VDL Weweler air suspension systems are low maintenance systems. For this reason, all moving
parts are rubber/steel Bushing; this avoids the need for lubrication during regular service intervals.
The specified torque settings and high clamping forces ensure that the steel inner bushes cannot
turn. The rubber part of the component accommodates the turning movement, when required.
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
3
2. MAINTENANCE WORK
(FOR DETAILLED DESCRIPTION SEE FOLLOWING PAGES)
Operations to be done each time before driving off: - Ensure that the air reservoir of braking and air suspension systems have reached their
operating pressure. - Drain the water and condensation from the system. - Check air suspension bellows for signs of damage and incorrect seating. After maneuver of
a vehicle without air pressure, make sure to raise the vehicle before driving. Raise the
unladen vehicle to maximum height by operating the raise-lower valve. This operation
ensures pretending air spring damage as a result of the flexmember foulding between
piston and beadplate of the airspring. I
NITIA
LLY
AFT
ER
2 W
EE
KS
*
EV
ER
Y 2
6 W
EEK
S
(T
WIC
E A
NN
UA
LLY
)
AN
NU
ALLY
**
- Visual inspection. Check all component parts for damage and wear. ●
1 Check condition of air springs. ●
2 Check shock absorber fastening for the correct torque loading. Inspection of torque settings with a calibrated torque wrench:
A: M20 (A/F 30) M = 450 Nm (tighten on nut side) B1: M16 (A/F 24) M = 300 Nm (tighten on nut side) B2: M20 (A/F 30) M = 450 Nm (tighten on nut side)
When mounting a new shock absorber kit: A: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side) B1: M16 (A/F 24) M = 170 Nm + 270° tightening angle (tighten on nut side) B2: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side)
● ●
3 Check the axle-clamp bolts for the correct torque loadings. Inspection of torque settings with a calibrated torque wrench:
A: M24 (A/F 36) M = 650 Nm B: M27 (A/F 41) M = 750 Nm
When mounting new axle clamp bolts: A: M24 (A/F 36) M = 800 Nm (+50/-0) B: M27 (A/F 41) M = 750 Nm + 180° tightening angle
● ●
4 Check the pivot bolts for the correct torque loadings. Inspection of torque settings with a calibrated torque wrench:
M27 (A/F 41) M = 750 Nm When mounting new trailing arms:
M27 (A/F 41) M = 950 Nm (+50/-0) + at least ¼ of the thread surface greased
● ●
5 Check air spring & support fastening for the correct torque loadings. Inspection of torque settings with a calibrated torque wrench:
A: M12 (A/F 19) M = 30 Nm B: M12 (A/F 19) M = 40 Nm
When mounting new air springs: A: M12 (A/F 19) M = 30 Nm (+10/-0) B: M12 (A/F 19) M = 66 Nm (+0/-16)
● ●
6 Check bump fastening for the correct torque loadings. Inspection of torque settings with a calibrated torque wrench:
M12 (A/F 19) M = 30 Nm When mounting new bumps:
M12 (A/F 19) M = 30 Nm (+10/-0)
● ●
7 Check axle lift & splitter for the correct torque loadings. See axle lift & splitter data sheets for the correct torque settings for each axle lift & splitter.
● ●
* After the first run under load conditions.
** Under extreme conditions with more frequency.
4
2A
6 5A
1
7
2B2
2B1
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
4
1. AIR SPRING VISUAL CHECK
Check air springs, every 6 months, for external damage like surface
cracking, abrasion, trapped debris etc.
Notice:
No welding should be carried out on the steel parts of the air springs
and pressure vessel! The air suspension should only be filled with
compressed air when mounted on the vehicle. The maximum pressure
in the air spring shouldn’t exceed 10 bar.
2. SHOCK ABSORBERS
Check shock absorber fastening annually and initially after 2 weeks.
Inspection of torque settings with a calibrated torque wrench:
A: M20 (A/F 30) M = 450 Nm (tighten on nut side)
B1: M16 (A/F 24) M = 300 Nm (tighten on nut side)
B2: M20 (A/F 30) M = 450 Nm (tighten on nut side)
When mounting new shock absorber kit:
A: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side)
B1: M16 (A/F 24) M = 170 Nm + 270° tightening angle (tighten on nut side)
B2: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side)
During vehicle maintenance shock absorbers are often replaced or
criticised due to symptoms of leakage. Shock absorbers, covered
with a film of oil, don’t have to be leak in any case. The surface of the
piston rod allows a small amount of lubrication of the seals
during each stroke. The piston rod causes with this movement of the
cylinder a microscopic volume of oil to be ejected from the shock
absorber. At high operation temperatures a “haze of oil” can be
formed which will later settle as a film on the seal and outer cylinder.
This effect, which has a function, should not be interpreted as a
failure of the shock absorber.
PLEASE NOTE THE FOLLOWING:
Check the shock absorber in dry conditions. Not in rainy weather conditions.
Light “sweating” is allowed.
With a failure “leakage” the shock absorber will lose all of its oil.
If in doubt, clean the shock absorber and check again after two days.
In case of failed shock absorber bushes, the shock absorber concerned must be replaced.
Turning the shock absorber enables you to simply detect excessive wear of rubber bushes.
Observing the specified torque setting ensures that the steel inner bush will not get twisted and that
the torsional motion is accommodated by the rubber part alone.
2B1
2B2
2A
1
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
5
3. AXLE-CLAMP BOLTS
Check axle-clamp bolts fastening annually and initially after 2 weeks.
Inspection of torque settings with a calibrated torque wrench:
A: M24 (A/F 36) M = 650 Nm
B: M27 (A/F 41) M = 750 Nm
When mounting new axle clamp bolts:
A: M24 (A/F 36) M = 800 Nm (+50/-0)
B: M27 (A/F 41) M = 750 Nm + 180° tightening angle
When replacing: tighten front M24 nuts first, subsequently the rear M27 nut!!
4. PIVOT BOLTS
Check pivot bolts fastening annually and initially after 2 weeks.
Using the specified torque settings ensures that the steel inner
bush (5) will not get twisted and the torsional motion is
accommodated by the rubber part (4) alone.
Check bushes, move the vehicle back and forth slightly with the
brake applied, or lever the rolled spring ends with the aid of a bar.
No play should be present in the rolled spring eye (6) when doing so.
If the fastening is loose the pivot bolt (2) may be worn or damaged.
Replace damaged parts immediately!
Check the wear plates (3) that are located on the hanger bracket (1).
If these are worn to the point that perfect clamping of the
steel inner bush (5) is no longer insured, replace the complete rubber
bush and the wear plates.
Inspection of torque settings with a calibrated torque wrench:
M27 (A/F 41) M = 750 Nm
When mounting new trailing arms:
M27 (A/F 41) M = 950 Nm (+50/-0) + at least ¼ of the
thread surface greased.
Also when mounting a trailing arm on a system with alignment in the hanger bracket, align the
system according to IM-141.
5. AIR SPRINGS
Check air spring fastening annually and initially after
2 weeks.
The different types of air springs can be mounted directly on the
tail end.
Inspection of torque settings with a calibrated torque wrench:
A: M12 (A/F 19) M = 30 Nm
B: M12 (A/F 19) M = 40 Nm
When mounting new air springs:
A: M12 (A/F 19) M = 30 Nm (+10/-0)
B: M12 (A/F 19) M = 66 Nm (+0/-16)
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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6. BUMP STOPS
The air suspension systems have been engineered so that the shock absorber acts as the down
wards suspension stop.
The shock absorbers can withstand heavy-duty road conditions, which obviates the need for
arrester cables or other suspension stops.
In order to cope with the situation where the air suspension system has
lowered without air, a bump above the trailing arm acts as a buffer. If
an air spring failure develops, the bump above the trailing arm enables
you to run (without air) at very low speed for a short period of time. This
will help you to get to the nearest service station. To prevent further
damage, always make sure that there is enough clearance for all moving
parts.
Inspection of torque settings with a calibrated torque wrench:
M12 (A/F 19) M = 30 Nm
When mounting new bumps:
M12 (A/F 19) M = 30 Nm (+10/-0)
7. AXLE LIFT & SPLITTER
Check axle lift & splitter fastening annually and initially
after 2 weeks.
The torque settings for the axle lift & splitter depend on the
type of axle lift and/or splitter.
See the axle lift & splitter data sheets for the corresponding
torque settings for each axle lift & splitter.
3. GENERAL INFORMATION
Lifting and lowering valve
Use the raise-lower valve ONLY for loading and unloading.
When driving the vehicle, be sure that you have selected “driving position” on the valve.
Driving with the air suspension valve set to “RAISE” may cause damage to the load, the
semi-trailer, the brakes and the suspension system, and leads to shock absorber overloading
and eventually the failure of the system.
No welding should be performed at the trailing arm!
7
6
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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4. MBS AIR SUSPENSION SYSTEM INSTALLATION INSTRUCTIONS & GUIDELINES
1. Assembly of MBS trailing arm
1. Set the spring supports to the
required spring track
Place the spring in the pivot bolt
holder and use the pin to hold it in
place
2. Place the zinc plate on the spring
3. Position the axle on the springs.
The axle should be positioned
symmetrically to the springs
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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4. Position the axle seat on the
axle. The axle seat should
contact the spring as indicated
(red line ref. 3). Rotate the axle
if necessary to position the
groove of the axle so that the
key of the axle seat locks in.
Mount the M24 bolts loosely,
include the parts in between in
the right orientation (see ref.2).
(During Tightening restrain
bolt heads to prevent
rotation. )
5. Position the tail end with the
right offset (ref. 4) and hold it in
position while mounting the M27
bolt.
6. Mount the M27 bolt and nut
loosely, including the washer in
the right position (ref. 5).
2
5
4
3
2
OR
5
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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7. Tighten the M24 nuts (preferred simultaneously) at the specified torque.
8. Tighten the M27 nut at the specified torque.
IMPORTANT: FIRST TIGHTEN
THE M24 NUTS AND THEN THE M27 NUT
M24 nuts: 800 Nm +50/-0 Nm M27 Nut: 750 Nm + 180°
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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9. Mounting of the shock absorbers (see page. 4)
There are two shock absorber mounting holes on the hanger bracket and depending on the ride
height of the suspension.
Position A Position B
2A: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side)
2B1: M16 (A/F 24) M = 170 Nm + 270° tightening angle (tighten on nut side)
2B2: M20 (A/F 30) M = 550 Nm (+50/-0) (tighten on nut side)
Warning: The sticker or engraving should always face towards the trailing arm.
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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After step 12 there are two options to complete the system assembly:
a. First paint the trailer chassis including the hanger brackets and then mount the air
suspension with axle to the trailer chassis (follow steps 13A-13H).
b. First mount the air suspension with axle to the trailer chassis and then paint the complete
system assembly (follow steps 14A-14H).
2. Assembly to the trailer chassis
10. Positioning + welding of the
hanger brackets.
(WM-C18)
See chassis reinforcement
recommendation in
appendix E.
(WM-C22)
11. Positioning + welding of the
bracings.
(WM-C15-GB)
12. Positioning holes for the air
spring & bump.
(see system drawing)
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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3. Paint instructions BEFORE mounting the air suspension with axle to the trailer
chassis
13A. Paint preparation.
Cover all areas which
must be clear from
paint.
(see IM-142)
13B. After painting mount
bumps.
(see page 3)
13C. Place wear plates &
suspension system
on the chassis with
hanger brackets after
painting.
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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13D. Place pivot bolts and
tighten the pivot bolts at
ride height. Align the
axle in the hanger
bracket.
Tighten AFTER aligning,
see step 13E.
(see page 3)
13E. Align all three axles
within tolerances.
(see IM-141)
A = Kingpin.
B to G are axle centres.
Tighten pivot bolts
(see step 13D).
13F. Weld the wear plates
(see WM-C20)
(this application is only
for the Australian
market).
Ensure that after welding
damages are repainted
well.
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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13G. Place shock absorbers so
that the code can be
read. And, if present,
follow the instructions on
the shock absorber.
Use a tool between the
tail end & chassis to keep
the system at ride height
and prevent the system
from dropping down on
the chassis. Tighten at
torque.
(see page 3)
13H. Final assembly.
Mount air spring
bellows.
Tighten top and bottom
at torque.
(see page 3)
13I. Finished product (Ready for wheel mounting).
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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4. Paint instructions AFTER mounting the air suspension with axle to the trailer
chassis
14A. Place wear plates &
suspension system on
the chassis with hanger
brackets.
14B. Place pivot bolts and
tighten the pivot bolts at
ride height. Align the
axle in the hanger
bracket.
Tighten AFTER aligning,
see step 14C.
(see page 3)
14C. Align all three axles
within tolerances.
(see IM-141)
A = Kingpin.
B to G are axle centres.
Tighten pivot bolts
(see step 14B).
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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14D. Weld the wear plates
(see WM-C20)
(this application is only
for the Australian
market)
14D. Place shock absorbers so
that the code can be
read. And, if present,
follow the instructions on
the shock absorber.
Use a tool between the
tail end & chassis to keep
the system at ride height
and prevent the system
from dropping down on
the chassis. Tighten at
torque.
(see page 3)
14E. Paint preparation.
Place a painting tool
between the tail end
& chassis to
prevent the system
from dropping down
on the chassis before
painting.
PAINTING TOOL (SHAPE & MATERIAL IS FREE)
MAINTENANCE AND INSTALLATION MANUAL - WSM-MBSA-EN-REV. I
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14F. Painting suspension
system + trailer chassis.
14G. Final assembly.
Mount air springs &
bumps on all axles.
Tighten at torque.
(see page 3)
14H. Finished product (Ready for wheel mounting).