Blueair BBB90 - 4B Installation manual

Auxiliary Air Suspension
Installation Manual
L.MAS.10D.C.M
(RWD Single and Double tire)
Nissan NV400, 2010 Onwards
Opel, Vauxhall Movano 2, 2010 Onwards
Renault Master X62 2010 Onwards
August 2012
www.dunlopsystems.com
Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
CONTENTS
1.
2.
3.
4.
5.
FOREWORD ..........................................................
INTRODUCTION ....................................................
VERY IMPORTANT NOTES ........................................
OVERVIEW ...........................................................
INSTRUCTIONS FOR INSTALLATION .........................
3
4
5
6
7
5.1. Recommended Tightening Torque.................................................. 7
5.2. Installation of the air suspension at the left side .............................. 8
5.3. Installation of the air suspension at the right side ............................ 8
5.4. Fitting of Inflator Console ............................................................. 9
5.5. Tube Connection and Disconnection, Cutting and Routing ............... 11
5.6. Spring Inflation......................................................................... 12
5.7. Spring Alignment ...................................................................... 13
5.8. Maintenance............................................................................. 13
5.9. Check list ................................................................................. 14
5.10. Installation Drawings ............................................................... 15
6. EPILOGUE ............................................................ 16
Dunlop Systems and Components
Het Wegdam 22
7496 CA Hengevelde
Nederland
Tel. +31 (0)547 33 30 65
Fax. +31 (0)547 33 30 68
Dunlop Systems and Components
Holbrook Lane
Coventry CV6 4QX
United Kingdom
Tel. +44 (0)24 7629 3300
Fax. +44 (0)24 7629 3390
www.dunlopsystems.nl
© 2008, Dunlop Systems and Components
2
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
1. FOREWORD
This manual provides instructions for the installation of an auxiliary air
suspension kit, developed specifically for the Renault Master X62, Opel/
Vauxhall Movano 2 and Nissan NV400 (2010 onwards) rear wheel drive
double tire and single tire. To ensure correct installation of the kit, it is
strongly recommend that these instructions are read thoroughly before
commencing any installation work. Installation should only be carried out
by a suitably qualified mechanic or specialist installation facility. Dunlop
Systems and Components 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 and signed by a qualified fitter, and that a copy is
returned to Dunlop Systems and Components by post, fax or email.
3
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
2. INTRODUCTION
Thank you for choosing an auxiliary air suspension kit from the range
offered by Dunlop Systems and Components. Auxiliary air suspension is
fitted in tandem with the standard steel springs of the vehicle
suspension, and provides enhancements in terms of both the stability of
the vehicle and the comfort of the passengers…
Vehicle Levelling
Simply by varying the air pressure in the springs, the vehicle can be
levelled both front-to-rear and side-to-side. Keeping the vehicle
level optimises stability, ensures correct headlamp beam distribution
and reduces tyre wear arising from uneven distribution 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 repeated or constant loading.
Any sagging already present can be compensated-for. This is a
particular benefit for motorhomes, which are always fully laden.
Ride Comfort
Air springs help to absorb shock loads from uneven road surfaces,
therefore general ride quality is much improved.
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L.MAS.10D.C.M
3. VERY IMPORTANT NOTES
Gross Vehicle Weight (GVW)
Air assist kits are not in themselves 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
Vehicle Uprating
Despite the above words of caution, it is possible to upgrade the weight
rating of your vehicle. This must be carried-out by a specialist supplier
that will…

carry out any necessary modifications in addition to fitting the air
assist kit

complete documentation as necessary to inform the Vehicle and
Operator Services Agency (VOSA) – a mandatory requirement

supply and fit a new weight plate to replace the original plate
supplied with the vehicle
This process applies to United Kingdom registered vehicles. The process
in other countries may be different.
Safety Guidance Note
The following very useful guidance note is available for free download
from the Health and Safety Executive (HSE)…
PM85, July 2007 Safe recovery (and repair) of buses and coaches fitted
with air suspension
The uniform resource locator (URL) for this document is…
http://www.hse.gov.uk/PUBNS/pm85.pdf
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
4. OVERVIEW
The diagram below is an overview of the complete assembly...
POS 1 2 3 4 5 6 7 8 9 10 ARTIKEL NUMBER OP.LB.170‐2.CPL 65.05.00.1.01 DIN 933‐M8x16 DIN 933‐M8x25 65.06.00.1.04.01 65.06.00.1.04.02 DIN 7991‐M8x12 DIN 125A‐M8 DIN 985‐M8 DESCRIPTION 170/2 AIR BELLOW UPPER BRACKET DISC SPRING WASHER 8 x 13 HEXAGON BOLT M8 x 16 HEXAGON BOLT M8 x 25 LOWER PLATE FIXATION BRACKET LOWER PLATE M8 x 12 COUNTER SUNK BOLT WASHER M8 SELF LOCKING NUT M8 AMOUNT 2 2 4 4 4 2 2 4 4 4 The kit is also supplied with black and blue air hose and an inflation
possibility (See Section 5.4)
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L.MAS.10D.C.M
5. INSTRUCTIONS FOR INSTALLATION
Preparation and Precaution
Before beginning installation, ensure that you have sufficient
clearance between the axle and the chassis (at least 25cm). Use
a jack if necessary. Install at one side of the vehicle at a time.
Pay attention to your safety at all times during installation always use axle stands to support the vehicle!
Start by jacking up the rear side till approximately driving level
and measure the distance between the rear axle and the chassis
at the location of the bump stop. This should be app. 14 cm. If
this is app. 18 cm you will need a 3convolute air bellow.
5.1 Recommended Tightening Torque
During fitting of the air suspension system, it is recommended that nuts
and bolts are tightened in accordance with the following table...
METRIC TORQUE CHART in N.m Aluminium SIZE CLASS 8.8 CLASS 10.9 and PA6G  When both the bolt and nut are made
M6 x 1 M8 x 1.25 M10 x 1.25* M10 x 1.5 M12 x 1.75 M16 x 2  For all other materials, tightening
10 23 51 48 83 200 14 34 72 67 117 285 4 9 20 18 31 80 from steel use either class 8.8 or 10.9
torque is left to the discretion of a
person skilled in the art
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L.MAS.10D.C.M
The following instructions make reference to the diagrams on pages 14 to
16 inclusive.
5.2 Installation of the air suspension at left side
1. Remove the bump stop. You can easily push the bump stop out of
it’s holder. The M10 bolt is to be reused for the mounting of the upper bracket (Photo 1—7).
2. Now there is space created to install the lower plate and air bellow.
3. Attach the lower plate with two M8 x12 counter sunk bolts (Photo 8),
take care that the air nipple will be at the inside of the chassis.
4. Lift the rear side of the assembly a bit (Photo 9) so you can easily
shift the assembly from the inside on it’s place (Photo 10—11).
5. The integrated clamps will keep the assembly on it’s place, they
have to be in between the two ribs of the anti roll bar bracket (Photo
12).
6. The middle stop positions the plate (Photo 12).
7. Now install the little bracket at the other side of the lower plate with
the two hexagon M8 x 25 bolts, washers and nuts (Photo 13—18).
8. Also this little bracket has to be in between the two ribs of the anti
roll bar bracket (Photo 18).
9. Install the upper bracket with it’s original bolt (Photo 6, 19 & 20).
The hole to guide the air hose trough has to be on the inside.
10. Remove the plug (Photo 21).
11. Guide the black air hose through the hole on the inside and connect
it to the air bellow (Photo 22, 23). Caution! Don’t tighten the special
nut of the air line not to tight (See Section 5.5).
12. Bring the air bellow into position on the rear axle and install both M8
bolt with disc washer finger tight at the top side. (see Photo 24).
13. Before tightening all bolts and nuts definitely, install the right side.
5.3 Installation of the air suspension at the right side
1. Item 1 till 12 are identical to the left side (accept that the right side
we use blue hose and of course is the right side mirror wise).
14. Bring the vehicle till driving height (when the vehicle is almost totally
empty you have to bring weight into the vehicle). Driving height is
app. 13.5 cm, of course can this height be modified a little on
request of the Vehicle owner.
15. Before tightening all bolts and nuts definitely (See section 5.1), the
air bellow needs to be aligned. (See Section 5.7)
16. Now you can guide the air hoses (See Section 5.5)
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Nissan NV400
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Renault Master
L.MAS.10D.C.M
5.4 Fitting of Inflator Console
STANDARD
OPTION 1
OPTION 2
OPTION 3
Your kit is supplied with one of the inflator console options shown above…

STANDARD : Two valves and a small bracket

OPTION 1
: Two valves in a console with two independent 10-bar
pressure gauges

OPTION 2
: Two valves in a console 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 2.2-litre at
pressure.
A special dashboard panel is available for
OPTION 1 and OPTION 2
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Opel Movano
Renault Master
L.MAS.10D.C.M
Mount the console in a position of your choice whereby it is firmly fixed,
has some protection from the environment (particularly important for the
console with gauges) and is easily accessible.
Suggested possible
locations include...
‘Standard’ Console…
 on the rear bumper
 at the rear beside the license
plate
 on the chassis next to a rear
wheel
 in a service shutter
(motorhomes)
 beside the fuel cap
‘Option 1’, ‘Option 2’ or ‘Option 3’
Console…
 in the vehicle cabin, within 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 information please ask your dealer.
The photograph below shows all of the parts of Comfort Package ‘Option
2’...
Comfort Package ‘Option 2’
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Opel Movano
Renault Master
L.MAS.10D.C.M
5.5 Tube Connection and Disconnection, Cutting and Routing
Connection and Disconnection
Tubes are connected as shown by the diagrams below...
A
A.
B.
C.
B
C
Slide a nut over the end of the tube
Push the tube onto the connector as far as possible
Feed the nut up to the connector, fully tighten by hand and finally
tighten one additional 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
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Renault Master
L.MAS.10D.C.M
Routing
Study the underside of the vehicle and decide how to route each branch
of the air circuit…
 To minimise the risk of chafing, avoid running tubing over metal
edges as much as possible
 Avoid close proximity to heat sources such as the exhaust assembly
 Choose a route that provides as much protection as possible from
dirt, debris and any solid objects that may impact the underside of
the vehicle
It is recommended that tubes are guided alongside brake lines as much
as possible.
Use cable ties (‘tie wraps’) to secure tubing to the chassis, taking
care not to over-tighten them.
5.6 Spring Inflation
Once installation of the air assist kit is complete, inflate the springs via
the inflator console taking careful note of the following...
Maximum and Minimum Pressure
Maximum Pressure 7.0bar
Minimum Pressure 0.5bar
Do not exceed 7.0bar (101psi), which is the recommended
maximum charge pressure for the air springs.
The springs may be deflated if the vehicle is to be stored for a
lengthy period without use, but a pressure of at least 0.5bar
(7.25psi) should be maintained at all times in order to avoid
possible compression damage to the springs.
It is wise to hand over the vehicle 24 hours after the installation is done.
Just to assure the customer will leaf with an airtight system.
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
5.7 Spring Alignment
Spring out of alignment
mounting plate axes offset
Spring
in
alignment
mounting plates parallel
and coaxial
CAUTION!
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 13.5cm) and ensure that the springs are
correctly aligned.
5.8 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…

to maintain air pressure in the springs. Much like a tyre, the system
may lose a little air over time.

to keep the air bellows clean. It is suggested that, when washing
the vehicle, the bellows are inspected and cleaned as necessary
(preferable by spraying).
Look in particular for stones or grit
trapped between convolutes, as this may damage the bellow.

Check before and after the winter period the wax coating. Re-wax
when necessarily
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
5.9 Check List
Before driving the vehicle following completion of installation of the
auxiliary air suspension system, please check...
...all bolts tightened to the recommended torque (Page 8)?
2
...air springs set in alignment (Section 5.4)?
...enough free space around the air springs to avoid wearing?
...all metal parts wax coated (Section 5.5)?
...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.
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Opel Movano
Renault Master
L.MAS.10D.C.M
5.10 Installation Drawings
15
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
1
2
3
4
5
6
7
8
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
9
10
11
12
13
14
15
16
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Opel Movano
Renault Master
L.MAS.10D.C.M
17
18
19
20
21
22
23
24
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Nissan NV400
Opel Movano
Renault Master
L.MAS.10D.C.M
6. EPILOGUE
Dunlop Systems and Components hopes that you enjoy the benefits that
your air suspension system will provide for you. To ensure optimal
performance, we advise that you have your system checked frequently
by qualified personnel. As recommended in the fitting instructions, it is
important to coat all the steel parts with a protective substance such as
body wax.
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 fitter and a copy is returned to
Dunlop Systems and Components by fax, post or e-mail.
As a condition of your warranty, modifications to the system may only be
carried out by personnel of Dunlop Systems and Components or an
appointed agent.
Enquiries
For general enquiries please either telephone…
Dunlop Systems and Components Nederland : +31 (0)547 33 30 65
Dunlop Systems and Components UK
: +44 (0)24 7629 3300
...or e-mail info@dunlopsystems.nl or info@dunlopsystems.com.
19
www.dunlopsystems.com
Auxiliary Air Suspension
Dunlop Systems and Components
Het Wegdam 22
7496 CA Hengevelde
Nederland
Tel. +31 (0)547 33 30 65
Fax. +31 (0)547 33 30 68
Dunlop Systems and Components
Holbrook Lane
Coventry CV6 4QX
United Kingdom
Tel. +44 (0)24 7629 3300
Fax. +44 (0)24 7629 3390
www.dunlopsystems.com