Dunlop L.412.4.C.M, Installation Manual

Page 1: ...L 412 C M and L 412 4 C M MERCEDES BENZ SPRINTER 408D 416CDI 1995 2006 WDB 904 AND 4X4 VOLKSWAGEN LT 46 1995 2006 DOUBLE TIRES AND 4X4 INSTALLATION MANUAL DSCSYSTEMS NL ...

Page 2: ...2 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 3: ...tting of Lower Bracket 10 5 6 Fitting of Bellow to Lower Bracket 10 5 7 Modification of Load Sensing Valve LSV Assembly 10 5 8 Fitting of Inflator Console 11 5 9 Tube Connection and Disconnection Cutting and Routing 13 5 10 Bellow Inflation 14 5 11 Spring Alignment 15 5 12 Maintenance 15 5 13 Check List 16 6 Installation pictures 17 7 Epilogue 22 Contents 3 INSTALLATION MANUAL AUXILIARY AIR SUSPEN...

Page 4: ...ic 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 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 fitt...

Page 5: ...n 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 repea...

Page 6: ...esigned 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 to avoid compromising passenger safety to prevent possible damage to the vehicle for legal reasons IMPORTANT Load Sensing Valve LSV Adjust...

Page 7: ...LY ARE SHOWN OF THE LEFT SIDE BY THE DIAGRAM BELOW 20 10 1 4 3 20 17 24 21 25 13 6 9 11 12 27 18 2 8 22 26 16 19 23 29 25 14 28 15 7 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 8: ...olt M6 x 30 1 15 DIN 933 M8x16 Hexagon bolt M8 x 16 6 16 DIN 933 M8x20 Hexagon bolt M8 x 20 2 17 DIN 933 M8x25 Hexagon bolt M8 x 25 2 18 DIN 933 M8x30 Hexagon bolt M8 x 30 2 19 DIN 7991 M8x16 Counter sunk bolt M8 x 16 2 20 DIN 934 M8 Fixation nut M8 4 21 DIN 985 M6 Self locking nut M6 2 22 DIN 985 M8 Self locking nut M8 2 23 OB 0394 06 Flange nut M6 1 24 DIN 125A M10 Washer M10 4 25 DIN 125A M6 Wa...

Page 9: ...OWING INSTRUCTIONS MAKE REFERENCE TO THE DIAGRAMS ON PAGES 17 TO 21 INCLUSIVE 5 2 PREPARATION 1 Secure the front wheels use wheel chocks on both sides of both front wheels 2 Take the ground terminal from the battery when work to electricity is involved 3 Lift the rear of the vehicle till there is working space of approximately 15 cm between bump stop and rear axle TIGHTENING TORQUE IN Nm SIZE CLAS...

Page 10: ...nclusive Do not fully tighten at this stage because the bellow may require alignment once inflated see Section 5 11 Figure 30 5 5 FITTING OF LOWER BRACKET 1 Remove the two bolts from the bracket that attaches the torsion beam assembly to the axle Figures 16 and 17 2 Place the lower bracket over the axle then reattach the bracket that secures the torsion beam assembly to the axle thereby also secur...

Page 11: ... with two independent 10 bar pressure gauges and a rocker on off switch to operate the electric motor driven air compressor OPTION 3 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 1 9 litre or 0 5 gallon at press...

Page 12: ...thin reach and sight of the driver Beside under the driver seat in the wall of a cupboard motorhomes in a service shutter 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 informa...

Page 13: ...nal turn using 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 RECOMMENDED Electrician s Side Cutters NOT RECOMMENDED ...

Page 14: ...ed pressure is up to the discretion of the installer but is mostly between the 1 5 bar and the 4 5 bar The pressure for driving your vehicle is depending on the weight of the vehicle and the condition of the original springs Always keep in mind that you are using air assist suspension that means helper springs they are designed to help Do not let them take over the original springs Because our sys...

Page 15: ...s body wax The system does not require very much maintenance other than 1 To maintain air pressure in the springs Much like a tyre the system may lose a little air over time 2 To keep the air bellows clean It is suggested that when washing the vehicle the bellows are inspected and cleaned as necessary pre ferable by spraying Look in particular for stones or grit trapped between convolutes as this ...

Page 16: ... 5 11 Enough free space around the air springs to avoid wearing All metal parts wax coated Section 5 12 Manufacturer s declaration form completed and a copy returned A wait of 24 hours is recommended in order to ensure that the vehicle has maintained its stance and that there are no air leaks present 16 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND ...

Page 17: ...6 INSTALLATION PICTURES 17 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 18: ...1 3 5 7 2 4 6 8 18 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 19: ...9 11 13 15 10 12 14 16 19 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 20: ...17 19 21 23 18 20 22 24 20 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 21: ...le at ride height spring height approximately 13 14 cm and ensure that the springs are correctly aligned Spring out of alignment mounting plate axes offset Spring in alignment mounting plates parallel and coaxial 21 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 22: ...turer 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 address is info dscsystems nl As a condition of your warranty modifications to the system may only be carried out by personnel of DSC Nederland ENQUIRIES For general enqui...

Page 23: ...23 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION SPRINTER 408D 416CDI AND 4X4 VOLKSWAGEN LT 46 AND 4X4 1995 2006 JULY 2021 ...

Page 24: ... 22 7496 CA Hengevelde Nederland T 31 0 547 333 065 F 31 0 547 333 068 E info dscsystems nl W www dscsystems nl DUNLOP and the Flying D device are trademarks of Sumitomo Rubber Group and are used under license by DSC Nederland B V ...