Sumitomo Dunlop L.D02.C.M, Installation Manual

Page 1: ...L D02 C M CITROËN JUMPER RELAY 2002 2006 X244 FIAT DUCATO 2002 2006 X244 PEUGEOT BOXER 2002 2006 X244 INSTALLATION MANUAL DSCSYSTEMS NL ...

Page 2: ...2 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 3: ...and fitting of Upper Bracket 9 5 6 Fitting of Lower Bracket and Bellow 9 5 7 Fitting of Inflator Console 10 5 8 Tube Connection and Disconnection Cutting and Routing 12 5 9 Bellow Inflation 13 5 10 Spring Alignment 14 5 11 IMPORTANT Load Sensing Valve LSV Adjustment 14 5 12 Maintenance 14 5 13 Check List 15 6 Installation pictures 16 7 Epilogue 20 Contents 3 INSTALLATION MANUAL AUXILIARY AIR SUSPE...

Page 4: ...chanic 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 ...

Page 5: ...on 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 repe...

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

Page 7: ...2 4 DIN 127B M10 Spring washer M10 2 5 DIN 961 M10 x 1 25 x 25 HEXAGON BOLT M10 x 25 p 1 25 2 6 M8 Disc spring washer 8 7 DIN 933 M8x16 Hexagon bolt M8 x 16 8 Left side not in the assembly drawing NOT IN THE ASSEMBLY DRAWING Tie wraps Black hose An inflate option Declaration of conformity Installation manual 7 6 1 4 5 3 2 7 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIA...

Page 8: ...MAKE REFERENCE TO THE DIAGRAMS ON PAGES 16 TO 19 INCLUSIVE 5 2 PRELIMINARY STEP LSV SPRING LENGTH MEASUREMENT 1 Vehicles without an antilock braking system have a load sensing valve fitted This has a spring linkage as shown by Figures 14 to 18 inclusive Before beginning installation measure and record the length of the spring from the top mounting bracket to the tip of the linkage rod TIGHTENING T...

Page 9: ...ng Connect a tube to the bellow Use black tubing for the left hand bellow and blue for the right hand bellow 2 Remove the U bolts that attach a clamping plate to the leaf spring and then remove and discard the plate itself Figures 5 and 6 3 Place the U bolts over the lower bracket and through their original mounting holes Secure the bolts using the original washers and nuts Figures 7 and 8 Tighten...

Page 10: ...e 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 pres...

Page 11: ...ithin 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 inform...

Page 12: ...onal 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 13: ...sed 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 sy...

Page 14: ...allation see Preliminary Step Section 5 2 The adjustment ring has a screw that locks it to the rod when tightened and enables the ring to slide along the rod when loosened 5 12 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 1 To maintain air pressure in th...

Page 15: ...n 5 10 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 15 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOX...

Page 16: ...6 INSTALLATION PICTURES 16 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 17: ...1 3 5 7 2 4 6 8 Centre of vehicle Centre of vehicle 17 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 18: ...9 11 13 15 10 12 14 16 18 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 19: ... Before fully tightening the bolts that secure the air spring to the upper and lower brackets set the vehicle at ride height spring height approximately 13 14 cm and ensure that the springs are correctly aligned 19 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 20: ...cturer 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 enqu...

Page 21: ...21 INSTALLATION MANUAL AUXILIARY AIR SUSPENSION X244 CITROËN JUMPER RELAY FIAT DUCATO PEUGEOT BOXER 2002 2006 JULY 2021 ...

Page 22: ... 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 ...