MAINTENANCE & INSTALLATION MANUAL - K-Hitch · MAINTENANCE & INSTALLATION MANUAL VDL Weweler bv ... always make sure that there is enough clearance for all moving ... Use the raise-lower

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.


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.


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

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- 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


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


5

3. AXLE-CLAMP BOLTS

Check axle-clamp bolts fastening annually and initially after 2 weeks.


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.


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.


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

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.


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


7

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


8

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


9

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°


10

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.


11

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)


12

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.


13

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.


14

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).


15

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).


16

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)


17

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).


18

APPENDIX A : WM-C18


19

APPENDIX B : WM-C15-GB


20

APPENDIX C : IM-141


21

APPENDIX D : WM-C20


22

APPENDIX E : IM-142


23

APPENDIX F : WM-C22


24

APPENDIX G : WM-C24


25

APPENDIX H : IM-145

Documents

MAINTENANCE & INSTALLATION MANUAL - K-Hitch · MAINTENANCE & INSTALLATION MANUAL VDL Weweler bv ... always make sure that there is enough clearance for all moving ... Use the raise-lower