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ProVan.dk | +45 2530 4650 | [email protected] ProVan Semi Air Luftaffjedring Installationsvejledning Varenr. 2428/2429 Fiat Ducato, Peugeot Boxer, Citroën Jumper/Relay X250 Chassis Kit, ABS Vehicles Only

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ProVan.dk | +45 2530 4650 | [email protected]

DR.02.012426 / DR.02.012427 FIAT DUCATO

PEUGEOT BOXER CITROËN JUMPER / RELAY X250 / X290 CHASSIS KIT

INSTALLATION INSTRUCTIONS

ProVanSemi Air Luftaffjedring

InstallationsvejledningVarenr. 2428/2429

Fiat Ducato, Peugeot Boxer, Citroën Jumper/RelayX250 Chassis Kit, ABS Vehicles Only

ProVan.dk | +45 2530 4650 | [email protected]

2

Table of content

Introduction ......................................................................................................................p. 3

Safety-information

Special instructions for Air Connections

Hardware list.....................................................................................................................p. 4

Installation - step by step

Step 1. Prepare the Vehicle ........................................................................................... p. 6

Step 2. Mount Lower Bracket to Air Spring .......................................................... p. 7

Step 3. Install the Air Fittings ....................................................................................... p. 7

Step 4. Mount Upper Bracket to Air Spring .......................................................... p. 8

Step 5. Install the Air Spring Assembly .................................................................... p. 9

Step 6. Routing the Air Tubing .................................................................................. p. 15

TÜV Godkendelse ........................................................................................................p. 16

ProVan.dk | +45 2530 4650 | [email protected]

3

IntroductionVarenr. 2428/2429

The purpose of this publication is to assist with the installation of the ProVan Semi-Air air suspension kit.

It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information here includes a hardware list and step-by-step installation information.

ProVan reserves the right to make changes and improvements to its products and publications at any time. Contact ProVan at +45 2530 4650 or visit us online at ProVan.dk for the latest version of this manual.

Improtant safety notice!The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load listed for your vehicle.

Gross Vehicle Weight Rating: the maximum allowable weight of the fully loaded vehicle (including passengers and cargo). This number — along with other weight limits, as well as tire, rim size and inflation pressure data — is shown on the vehicle’s Safety Compliance Certification Label.

Payload: The combined, maximum allowable weight of cargo and passengers that the truck is designed to carry. Payload is GVWR minus the Base Curb Weight.

PrecautionsNever exceed the maximum and minimum recommended pressure limits:• Minimum Pressure - 1 Bar (14.5 p.s.i)• Maximum Pressure - 7 Bar (100 p.s.i)

While it is possible to inflate the system in static mode to 7 Bar (100 p.s.i.), it should not be necessary to exceed operating pressure in the region of 3.5 Bar (50 p.s.i.) at vehicle full GVW. This kit should not be used to carry any greater load than manufacturers stated GVW.To avoid damage to airsprings – When the kit has been installed, please ensure there is adequate clearance (25mm) around the airspring so the airspring does not come in contact with any other parts.

NEVER DRIVE WITH DEFLATED AIRSPRINGS!

Special Instructions for Air Connections• To cut the tubing correctly an appropriate cutter

must be used (not scissors)• When inserting the tubing into the connection,

it must be pushed in approximately 14mm until a ‘click’ is heard.

• To remove the tube, you must push the flange in on the connection and at the same time pull the tube. (No tool is necessary.)

• BEMÆRK, when a tube is removed it is important to trim 14mm from the end before reconnection.• It is advisable that LOCTITE or similar sealant be used on the threaded fittings.

9

40/15 Revision 6

Step 6: Routing the Air Tubing

Cut a long length of tubing in order to connect the valve to the nearest air spring. Do the same for the opposite side. Choose whether you want separate inflation valves for each side or one valve common to both sides using the T shaped connector. Use the nylon ties provided to tie the tubing up into a safe position.

When cutting the air tube, it is vital that the tube is not cut at an angle. This could cause an air leak. It is recommended that a tube cutter or a sharp blade.

Drill an 8mm (5/16”) hole and mount the inflation valve as shown in the diagram, pushing the valve through the hole from behind and attaching with 2 washers and a nut.

Cut the air tube to length, making sure the end is cut squarely, and push the end as far as possible into the back of the inflation valve.

IMPORTANT: Attach all tubing securely to the underneath of the vehicle using nylon ties. Do not attach to brake lines. Protect the tube with the sleeves provided where there are any sharp edges or sources of

heat. Tighten all fittings to the recommended torque

Examination: After assembly, inflate air springs and check all mounting bolts are tight. Screw all connections tight again. It must be ensured that the mounting brackets cannot move. If the plates touch the brake hose at the air springs, then these must be moved by suitable means.

ProVan.dk | +45 2530 4650 | [email protected]

4

Part name Amount Image/Description Part no.:

Upper Inner Bracket 2 2135825530

Upper Air Spring Bracket 2 2135825519

Lower Air Spring Bracket 2 2135825520

Air Spring 2 2135825086

Style 267 Airspring 2 For 2428 kit ONLY A01-760-6781

Style 26C Airspring 2 For 2429 kit ONLY A01-760-7339**

1/4” Tubing 5m 18 Feet 2135829414

Thermal Sleeve 2 2135820899

Nylon Tie Strap 15 Cable Ties 2135829036

5/16-18 x 3 1/2” Hex Bolt 4 Outer brackets to Inner brackets 2135823075

5/16-18 Hex Nut 4 For 5/16 Bolts 2135820687

5/16 Lockwasher 4 For 5/16 Bolts 2135820062

5/16 Flat Washer 4 For Inflation valves 2135823033

M10x1.25-30 Hex Head 2 Upper Inner Bracket to Chassis 2135823074

M10 Lockwasher 2 For M10 Bolts 7035828432

3/8-16 x 8” Carriage Bolt 8 2135823020

3/8-16 Flange Locknut 12** 8-carriage bolt, 4-2428 Air Spring 2135823022

1/2-13 x 3/4 Hex Bolt 2 For Bottom of 2429 Air Spring 2135823049

1/2” Flat Washer 2 For Bottom of 2429 Air Spring 2135820133

3/8-16 x 3/4 Hex bolt 4 2-Bottom of 2428, 4-top of 2429 2135820681

3/8” Flat Washer 2 Bottom of 2428 Air Spring 2135820532

1/4” to 1/4” Elbow Fitting 2 2135823031

1/4” Inflation Valve 2 2135823032

1/4” T-Piece 1 2135823025

**Please Note that the 7339 Air Spring may be supplied with Studs instead of Blind nuts. Four 3/8-24 Flange Locknuts will be supplied in this case.

The 2428 and 2429 kits share a bolt pack. Some fittings may not be needed in your installation.Do not be alarmed if you have pieces left over.

4

28/13 Revision 3

Kit Contents HARDWARE LIST

Name Quantity Picture/Description Part #

Upper Inner Bracket 2 2135825530

Upper Outer Bracket 2 2135825519

Lower Bracket - with 1/2" centre hole 2 2135825520

Bracket Strap 1/2" 4 2135825086

Style 267 Airspring 2 For 2428 kit ONLY A01-760-6781Style 26C Airspring 2 For 2429 kit ONLY A01-760-7339**1/4" Tubing 5m 18 Feet 2135829414Thermal Sleeve 2 2135820899Nylon Tie Strap 15 Cable Ties 21358290365/16-18 x 3 1/2" Hex Bolt 4 Outer brackets to Inner brackets 21358230755/16-18 Hex Nut 4 For 5/16 Bolts 21358206875/16 Lockwasher 4 For 5/16 Bolts 21358200625/16 Flat Washer 4 For Inflation Valves 2135823033M10x1.25-30 Hex Head 2 Upper Inner Bracket to Chassis 2135823074M10 Lockwasher 2 For M10 Bolts 70358284323/8-16 x 8" Carriage Bolt 8 21358230203/8-16 Flange Locknut 12** 8-carriage bolt, 4-2428 Air Spring 21358230221/2-13 x 3/4 Hex Bolt 2 For bottom of 2429 Air Spring 21358230491/2" Flat Washer 2 For bottom of 2429 Air Spring 21358201333/8-16 x 3/4 Hex bolt 4 2-Bottom of 2428, 4-Top of 2429 21358206813/8" Flat Washer 2 Bottom of 2428 Air Spring 21358205321/4" to 1/4" Elbow Fitting 2 21358230311/4" Inflation Valve 2 21358230321/4" T-Piece 1 2135823025

**Please Note that the 7339 Air Spring may be supplied with Studs instead of Blind nuts. Four 3/8-24 Flange Locknuts will be supplied in this case.

The 2428 and 2429 kits share a bolt pack. Some fittings may not be needed in your installation. Do not be alarmed if you have pieces left over.

4

28/13 Revision 3

Kit Contents HARDWARE LIST

Name Quantity Picture/Description Part #

Upper Inner Bracket 2 2135825530

Upper Outer Bracket 2 2135825519

Lower Bracket - with 1/2" centre hole 2 2135825520

Bracket Strap 1/2" 4 2135825086

Style 267 Airspring 2 For 2428 kit ONLY A01-760-6781Style 26C Airspring 2 For 2429 kit ONLY A01-760-7339**1/4" Tubing 5m 18 Feet 2135829414Thermal Sleeve 2 2135820899Nylon Tie Strap 15 Cable Ties 21358290365/16-18 x 3 1/2" Hex Bolt 4 Outer brackets to Inner brackets 21358230755/16-18 Hex Nut 4 For 5/16 Bolts 21358206875/16 Lockwasher 4 For 5/16 Bolts 21358200625/16 Flat Washer 4 For Inflation Valves 2135823033M10x1.25-30 Hex Head 2 Upper Inner Bracket to Chassis 2135823074M10 Lockwasher 2 For M10 Bolts 70358284323/8-16 x 8" Carriage Bolt 8 21358230203/8-16 Flange Locknut 12** 8-carriage bolt, 4-2428 Air Spring 21358230221/2-13 x 3/4 Hex Bolt 2 For bottom of 2429 Air Spring 21358230491/2" Flat Washer 2 For bottom of 2429 Air Spring 21358201333/8-16 x 3/4 Hex bolt 4 2-Bottom of 2428, 4-Top of 2429 21358206813/8" Flat Washer 2 Bottom of 2428 Air Spring 21358205321/4" to 1/4" Elbow Fitting 2 21358230311/4" Inflation Valve 2 21358230321/4" T-Piece 1 2135823025

**Please Note that the 7339 Air Spring may be supplied with Studs instead of Blind nuts. Four 3/8-24 Flange Locknuts will be supplied in this case.

The 2428 and 2429 kits share a bolt pack. Some fittings may not be needed in your installation. Do not be alarmed if you have pieces left over.

4

28/13 Revision 3

Kit Contents HARDWARE LIST

Name Quantity Picture/Description Part #

Upper Inner Bracket 2 2135825530

Upper Outer Bracket 2 2135825519

Lower Bracket - with 1/2" centre hole 2 2135825520

Bracket Strap 1/2" 4 2135825086

Style 267 Airspring 2 For 2428 kit ONLY A01-760-6781Style 26C Airspring 2 For 2429 kit ONLY A01-760-7339**1/4" Tubing 5m 18 Feet 2135829414Thermal Sleeve 2 2135820899Nylon Tie Strap 15 Cable Ties 21358290365/16-18 x 3 1/2" Hex Bolt 4 Outer brackets to Inner brackets 21358230755/16-18 Hex Nut 4 For 5/16 Bolts 21358206875/16 Lockwasher 4 For 5/16 Bolts 21358200625/16 Flat Washer 4 For Inflation Valves 2135823033M10x1.25-30 Hex Head 2 Upper Inner Bracket to Chassis 2135823074M10 Lockwasher 2 For M10 Bolts 70358284323/8-16 x 8" Carriage Bolt 8 21358230203/8-16 Flange Locknut 12** 8-carriage bolt, 4-2428 Air Spring 21358230221/2-13 x 3/4 Hex Bolt 2 For bottom of 2429 Air Spring 21358230491/2" Flat Washer 2 For bottom of 2429 Air Spring 21358201333/8-16 x 3/4 Hex bolt 4 2-Bottom of 2428, 4-Top of 2429 21358206813/8" Flat Washer 2 Bottom of 2428 Air Spring 21358205321/4" to 1/4" Elbow Fitting 2 21358230311/4" Inflation Valve 2 21358230321/4" T-Piece 1 2135823025

**Please Note that the 7339 Air Spring may be supplied with Studs instead of Blind nuts. Four 3/8-24 Flange Locknuts will be supplied in this case.

The 2428 and 2429 kits share a bolt pack. Some fittings may not be needed in your installation. Do not be alarmed if you have pieces left over.

4

28/13 Revision 3

Kit Contents HARDWARE LIST

Name Quantity Picture/Description Part #

Upper Inner Bracket 2 2135825530

Upper Outer Bracket 2 2135825519

Lower Bracket - with 1/2" centre hole 2 2135825520

Bracket Strap 1/2" 4 2135825086

Style 267 Airspring 2 For 2428 kit ONLY A01-760-6781Style 26C Airspring 2 For 2429 kit ONLY A01-760-7339**1/4" Tubing 5m 18 Feet 2135829414Thermal Sleeve 2 2135820899Nylon Tie Strap 15 Cable Ties 21358290365/16-18 x 3 1/2" Hex Bolt 4 Outer brackets to Inner brackets 21358230755/16-18 Hex Nut 4 For 5/16 Bolts 21358206875/16 Lockwasher 4 For 5/16 Bolts 21358200625/16 Flat Washer 4 For Inflation Valves 2135823033M10x1.25-30 Hex Head 2 Upper Inner Bracket to Chassis 2135823074M10 Lockwasher 2 For M10 Bolts 70358284323/8-16 x 8" Carriage Bolt 8 21358230203/8-16 Flange Locknut 12** 8-carriage bolt, 4-2428 Air Spring 21358230221/2-13 x 3/4 Hex Bolt 2 For bottom of 2429 Air Spring 21358230491/2" Flat Washer 2 For bottom of 2429 Air Spring 21358201333/8-16 x 3/4 Hex bolt 4 2-Bottom of 2428, 4-Top of 2429 21358206813/8" Flat Washer 2 Bottom of 2428 Air Spring 21358205321/4" to 1/4" Elbow Fitting 2 21358230311/4" Inflation Valve 2 21358230321/4" T-Piece 1 2135823025

**Please Note that the 7339 Air Spring may be supplied with Studs instead of Blind nuts. Four 3/8-24 Flange Locknuts will be supplied in this case.

The 2428 and 2429 kits share a bolt pack. Some fittings may not be needed in your installation. Do not be alarmed if you have pieces left over.

Hardware listVarenr. 2428/2429

ProVan.dk | +45 2530 4650 | [email protected]

Step 1. Prepare the Vehicle

Your vehicle is equipped with a rubber bump stop which is positioned on the frame directly above the axle. Remove this bump stop together with bracket and discard.

Bolt the Upper Inner Bracket to the chassis rail using the M10 bolts and lock washers (Torque to approx. 43Nm). Ensure that the slot cut out of the Upper Inner bracket is facing towards the centre of the vehicle. (Circled)

Step 1. Mount the Lower Bracket to the Air Spring

Fasten the Air Spring to the Lower Bracket.

For the 2428 kit use the 3/8-16 x 3/4 Hex Bolts and penny washers provided. (Torque to approx. 25-30Nm).

For the 2429 kit use the 1/2-13 x 3/4 Hex Bolts and penny washers provided.(Torque to approx. 38-43Nm).

Step 1. Install the Air Fittings

Install the elbow in the air inlet hole on the top plate of the air springs. Tighten until the elbow is pointing towards the centre of the vehicle.

We recommend that a sealant is used when attaching the elbow.

5

28/13 Revision 3

Step by Step Installation Step 1: Prepare the Vehicle

Your vehicle is equipped with a rubber bump stop which is positioned on the frame directly above the axle. Remove this bump stop together with bracket and discard.

Bolt the Upper Inner Bracket to the chassis rail using the M10 bolts and lock washers (Torque to approx. 43Nm). Ensure that the slot cut out of the Upper Inner bracket is facing towards the centre of the vehicle. (Circled)

Step 2: Mount the Lower Bracket to the Air Spring

Fasten the Air Spring to the Lower Bracket. For the 2428 kit use the 3/8-16 x 3/4 Hex bolts and penny washers provided. (Torque to approx. 25-30Nm).

For the 2429 kit use the 1/2-13 x 3/4 Hex Bolts and penny washers provided.

(Torque to approx. 38-43Nm).

Step 3: Install the Air Fittings

Install the elbow in the air inlet hole on the top plate of the air springs. Tighten until the elbow is pointing towards the centre of the vehicle.

We recommend that a sealant is used when attaching the elbow.

5

28/13 Revision 3

Step by Step Installation Step 1: Prepare the Vehicle

Your vehicle is equipped with a rubber bump stop which is positioned on the frame directly above the axle. Remove this bump stop together with bracket and discard.

Bolt the Upper Inner Bracket to the chassis rail using the M10 bolts and lock washers (Torque to approx. 43Nm). Ensure that the slot cut out of the Upper Inner bracket is facing towards the centre of the vehicle. (Circled)

Step 2: Mount the Lower Bracket to the Air Spring

Fasten the Air Spring to the Lower Bracket. For the 2428 kit use the 3/8-16 x 3/4 Hex bolts and penny washers provided. (Torque to approx. 25-30Nm).

For the 2429 kit use the 1/2-13 x 3/4 Hex Bolts and penny washers provided.

(Torque to approx. 38-43Nm).

Step 3: Install the Air Fittings

Install the elbow in the air inlet hole on the top plate of the air springs. Tighten until the elbow is pointing towards the centre of the vehicle.

We recommend that a sealant is used when attaching the elbow.

5

28/13 Revision 3

Step by Step Installation Step 1: Prepare the Vehicle

Your vehicle is equipped with a rubber bump stop which is positioned on the frame directly above the axle. Remove this bump stop together with bracket and discard.

Bolt the Upper Inner Bracket to the chassis rail using the M10 bolts and lock washers (Torque to approx. 43Nm). Ensure that the slot cut out of the Upper Inner bracket is facing towards the centre of the vehicle. (Circled)

Step 2: Mount the Lower Bracket to the Air Spring

Fasten the Air Spring to the Lower Bracket. For the 2428 kit use the 3/8-16 x 3/4 Hex bolts and penny washers provided. (Torque to approx. 25-30Nm).

For the 2429 kit use the 1/2-13 x 3/4 Hex Bolts and penny washers provided.

(Torque to approx. 38-43Nm).

Step 3: Install the Air Fittings

Install the elbow in the air inlet hole on the top plate of the air springs. Tighten until the elbow is pointing towards the centre of the vehicle.

We recommend that a sealant is used when attaching the elbow.

Installation - step by stepVarenr. 2428/2429

5

ProVan.dk | +45 2530 4650 | [email protected]

6

Step 4. Mount the Upper Bracket to the Air Spring

Position the Upper Outer Bracket onto the Air Spring ensuring that the elbow is exposed in the slot cut out of the bracket.

For the 2428 kit use 2x of the 3/8-16 Flange Locknuts provided.(Torque to approx. 20-25Nm).

For the 2429 kit use 2x of the 3/8-16 x 3/4 Hex bolts provided.(Torque to approx. 20-25Nm).

In some cases the 2429 air spring may have studs. Use Flange Locknuts provided.

2428 Kit

2429 Kit

Step 5. MInstall the Air Spring Assembly

Place the assembly on the Leaf Springs and position so that the Lower Bracket rests level on the Leaf Spring pack as shown in diagram. Bolt the Upper Outer Bracket (B) to the Inner Bracket (A).

This is achieved by placing 2x 5/16-18 x 3 1/2” Hex Bolt through the 2 side holes of the Upper Outer brackets.

Fix in place using the 5/16” nuts and lockwashers (Torque to approx. 22Nm).

Bolt the Lower Bracket in place through the square cut-outs (C) using the 3/8” carriage bolts and Bracket Straps (D) provided (Torque to approx. 20Nm).

6

28/13 Revision 3

Step 4: Mount the Upper Bracket to the Air SpringPosition the Upper Outer Bracket onto the Air Spring ensuring that the elbow is exposed in the slot cut out of the bracket.

For the 2428 kit use 2x of the 3/8-16 Flange Locknuts provided. (Torque to approx. 20-25Nm).

For the 2429 kit use 2x of the 3/8-16 x 3/4 Hex bolts provided. (Torque to approx. 20-25Nm).

In some cases the 2429 air spring may have studs. Use Flange Locknuts provided.

2428 kit 2429 kit

Step 5: Install the Air Spring Assembly

Place the assembly on the Leaf Springs and position so that the Lower Bracket rests level on the Leaf Spring pack as shown in diagram. Bolt the Upper Outer Bracket (B) to the Inner Bracket (A).

This is achieved by placing 2x 5/16-18 x 3 1/2" Hex Bolt through the 2 side holes of the Upper Outer brackets.

Fix in place using the 5/16” nuts and lockwashers (Torque to approx. 22Nm).

Bolt the Lower Bracket in place through the square cut-outs (C) using the 3/8” carriage bolts and Bracket Straps (D) provided (Torque to approx. 20Nm).

A

C

D Leaf Spring

B

6

28/13 Revision 3

Step 4: Mount the Upper Bracket to the Air SpringPosition the Upper Outer Bracket onto the Air Spring ensuring that the elbow is exposed in the slot cut out of the bracket.

For the 2428 kit use 2x of the 3/8-16 Flange Locknuts provided. (Torque to approx. 20-25Nm).

For the 2429 kit use 2x of the 3/8-16 x 3/4 Hex bolts provided. (Torque to approx. 20-25Nm).

In some cases the 2429 air spring may have studs. Use Flange Locknuts provided.

2428 kit 2429 kit

Step 5: Install the Air Spring Assembly

Place the assembly on the Leaf Springs and position so that the Lower Bracket rests level on the Leaf Spring pack as shown in diagram. Bolt the Upper Outer Bracket (B) to the Inner Bracket (A).

This is achieved by placing 2x 5/16-18 x 3 1/2" Hex Bolt through the 2 side holes of the Upper Outer brackets.

Fix in place using the 5/16” nuts and lockwashers (Torque to approx. 22Nm).

Bolt the Lower Bracket in place through the square cut-outs (C) using the 3/8” carriage bolts and Bracket Straps (D) provided (Torque to approx. 20Nm).

A

C

D Leaf Spring

B

6

28/13 Revision 3

Step 4: Mount the Upper Bracket to the Air SpringPosition the Upper Outer Bracket onto the Air Spring ensuring that the elbow is exposed in the slot cut out of the bracket.

For the 2428 kit use 2x of the 3/8-16 Flange Locknuts provided. (Torque to approx. 20-25Nm).

For the 2429 kit use 2x of the 3/8-16 x 3/4 Hex bolts provided. (Torque to approx. 20-25Nm).

In some cases the 2429 air spring may have studs. Use Flange Locknuts provided.

2428 kit 2429 kit

Step 5: Install the Air Spring Assembly

Place the assembly on the Leaf Springs and position so that the Lower Bracket rests level on the Leaf Spring pack as shown in diagram. Bolt the Upper Outer Bracket (B) to the Inner Bracket (A).

This is achieved by placing 2x 5/16-18 x 3 1/2" Hex Bolt through the 2 side holes of the Upper Outer brackets.

Fix in place using the 5/16” nuts and lockwashers (Torque to approx. 22Nm).

Bolt the Lower Bracket in place through the square cut-outs (C) using the 3/8” carriage bolts and Bracket Straps (D) provided (Torque to approx. 20Nm).

A

C

D Leaf Spring

B

6

28/13 Revision 3

Step 4: Mount the Upper Bracket to the Air SpringPosition the Upper Outer Bracket onto the Air Spring ensuring that the elbow is exposed in the slot cut out of the bracket.

For the 2428 kit use 2x of the 3/8-16 Flange Locknuts provided. (Torque to approx. 20-25Nm).

For the 2429 kit use 2x of the 3/8-16 x 3/4 Hex bolts provided. (Torque to approx. 20-25Nm).

In some cases the 2429 air spring may have studs. Use Flange Locknuts provided.

2428 kit 2429 kit

Step 5: Install the Air Spring Assembly

Place the assembly on the Leaf Springs and position so that the Lower Bracket rests level on the Leaf Spring pack as shown in diagram. Bolt the Upper Outer Bracket (B) to the Inner Bracket (A).

This is achieved by placing 2x 5/16-18 x 3 1/2" Hex Bolt through the 2 side holes of the Upper Outer brackets.

Fix in place using the 5/16” nuts and lockwashers (Torque to approx. 22Nm).

Bolt the Lower Bracket in place through the square cut-outs (C) using the 3/8” carriage bolts and Bracket Straps (D) provided (Torque to approx. 20Nm).

A

C

D Leaf Spring

B

ProVan.dk | +45 2530 4650 | [email protected]

7

Step 6. Routing the Air Tubing

Cut a long length of tubing in order to connect the valve to the nearest air spring. Do the same for the opposite side. Choose whether you want separate inflation valves for each side or one valve common to both sides using the T shaped connector. Use the nylon ties provided to tie the tubing up into a safe position.

When cutting the air tube, it is vital that the tube is not cut at an angle. This could cause an air leak. It is recommended that a tube cutter or a sharp blade.

Drill an 8mm (5/16”) hole and mount the inflation valve as shown in the diagram, pushing the valve through the hole from behind and attaching with 2 washers and a nut.Cut the air tube to length, making sure the end is cut squarely, and push the end as far as possible into the back of the inflation valve.

Important!• Attach all tubing securely to the underneath of the vehicle using nylon ties.• Do not attach to brake lines.• Protect the tube with the sleeves provided where there are any sharp edges or sources of

heat.• Secure all fixings to the recommended torque settings.

Examination:After assembly, inflate air springs and check all mounting bolts are tight. Screw all connections tight again. It must be ensured that the mounting brackets cannot move. If the plates touch the brake hose at the air springs, then these must be moved by suitable means.

9

40/15 Revision 6

Step 6: Routing the Air Tubing

Cut a long length of tubing in order to connect the valve to the nearest air spring. Do the same for the opposite side. Choose whether you want separate inflation valves for each side or one valve common to both sides using the T shaped connector. Use the nylon ties provided to tie the tubing up into a safe position.

When cutting the air tube, it is vital that the tube is not cut at an angle. This could cause an air leak. It is recommended that a tube cutter or a sharp blade.

Drill an 8mm (5/16”) hole and mount the inflation valve as shown in the diagram, pushing the valve through the hole from behind and attaching with 2 washers and a nut.

Cut the air tube to length, making sure the end is cut squarely, and push the end as far as possible into the back of the inflation valve.

IMPORTANT: Attach all tubing securely to the underneath of the vehicle using nylon ties. Do not attach to brake lines. Protect the tube with the sleeves provided where there are any sharp edges or sources of

heat. Tighten all fittings to the recommended torque

Examination: After assembly, inflate air springs and check all mounting bolts are tight. Screw all connections tight again. It must be ensured that the mounting brackets cannot move. If the plates touch the brake hose at the air springs, then these must be moved by suitable means.

9

40/15 Revision 6

Step 6: Routing the Air Tubing

Cut a long length of tubing in order to connect the valve to the nearest air spring. Do the same for the opposite side. Choose whether you want separate inflation valves for each side or one valve common to both sides using the T shaped connector. Use the nylon ties provided to tie the tubing up into a safe position.

When cutting the air tube, it is vital that the tube is not cut at an angle. This could cause an air leak. It is recommended that a tube cutter or a sharp blade.

Drill an 8mm (5/16”) hole and mount the inflation valve as shown in the diagram, pushing the valve through the hole from behind and attaching with 2 washers and a nut.

Cut the air tube to length, making sure the end is cut squarely, and push the end as far as possible into the back of the inflation valve.

IMPORTANT: Attach all tubing securely to the underneath of the vehicle using nylon ties. Do not attach to brake lines. Protect the tube with the sleeves provided where there are any sharp edges or sources of

heat. Tighten all fittings to the recommended torque

Examination: After assembly, inflate air springs and check all mounting bolts are tight. Screw all connections tight again. It must be ensured that the mounting brackets cannot move. If the plates touch the brake hose at the air springs, then these must be moved by suitable means.

9

40/15 Revision 6

Step 6: Routing the Air Tubing

Cut a long length of tubing in order to connect the valve to the nearest air spring. Do the same for the opposite side. Choose whether you want separate inflation valves for each side or one valve common to both sides using the T shaped connector. Use the nylon ties provided to tie the tubing up into a safe position.

When cutting the air tube, it is vital that the tube is not cut at an angle. This could cause an air leak. It is recommended that a tube cutter or a sharp blade.

Drill an 8mm (5/16”) hole and mount the inflation valve as shown in the diagram, pushing the valve through the hole from behind and attaching with 2 washers and a nut.

Cut the air tube to length, making sure the end is cut squarely, and push the end as far as possible into the back of the inflation valve.

IMPORTANT: Attach all tubing securely to the underneath of the vehicle using nylon ties. Do not attach to brake lines. Protect the tube with the sleeves provided where there are any sharp edges or sources of

heat. Tighten all fittings to the recommended torque

Examination: After assembly, inflate air springs and check all mounting bolts are tight. Screw all connections tight again. It must be ensured that the mounting brackets cannot move. If the plates touch the brake hose at the air springs, then these must be moved by suitable means.

ProVan.dk | +45 2530 4650 | [email protected]

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28/13 Revision 3

TÜV Certificate Available, contact Drive-Rite for details

Unit 626 Kilshane Avenue, North West Business Park, Ballycoolin, Dublin 15, Ireland Telephone: +353 1 8612 632 Fax: +353 1 8612 647 email:[email protected]

Web: www.driveriteair.com

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40/15 Revision 6

FULL REPORT AVAILABLE FOR DOWNLOAD AT WWW.DRIVERITEAIR.COM

Unit 626 Kilshane Avenue, North West Business Park, Ballycoolin, Dublin 15, Ireland Telephone: +353 1 8612 632 Fax: +353 1 8612 647 email:[email protected]

Web: www.driveriteair.com

TÜV GodkendelseVarenr. 2428/2429

Fulde TÜV Godkendelse for varenr. 2428/2429 kan hentes fra vores hjemmeside ProVan.dk