BPW Air Suspension Maintenance Instructions

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Series ALO/SLO Series ALO/SLO with two-sided axle lift
Series ALM/SLM Series ALM/SLM with Kombi-Air Bag II
Series ALU/SLU Series DLU - Airlight
Direct
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BPW Air suspensions
Visual inspection. Check all component parts for damage and wear.
1 Check condition of air bags.
2 Check air suspension level valves for condition,
sealtightness and general tightness.
3 Check shock absorber fastening for tightness.
Tightening torques with a torque wrench:
M 24 M = 420 Nm (390460 Nm)
for aluminium hanger brackets M = 320 Nm (300350 Nm)
4 Check spring mounting kit for tightness.
M 22 M = 550 Nm (510600 Nm)
2)
M 24 M = 650 Nm (605715 Nm)
5 Check spring pivot bolts for tightness.
hanger brackets up to 07/2001: M 30 M = 750 Nm (700825 Nm)
hanger brackets from 08/2001: M 30 M = 900 Nm (840990 Nm)
channel cross member: M 30 M = 900 Nm (840990 Nm)
6 Check air bag fastening for tightness.
M 12 M = 66 Nm
M 16 M = 230 Nm
7 Check axle lift for tightness.
supporting arm M 16 M = 230 Nm
cylinder M 16 M = 180 210 Nm
8 Check strap. Check condition and fastening.
1)
under extreme conditions, more frequently.
2)
When mounting new spring mounting kit components for Airlight II:
Tightening torque: M 22 M = 550 Nm + 90 angle tightening
3)
for use outside Europe
Valid: 01.11.2003
Maintenance work after expiry of the warranty period
Overview
For detailed description see pages 34 - 39
Visual checks or maintenance work
during the warranty period, see pages 9 11
Maintenance
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2 Air installation circuit
After expiry of the warranty period:
Recommended halfyearly, after 1 year
offroad or 2 years onroad outside Europe
Recommended annually, after 3 years
offroad, 5 or 8 years onroad
Check air installation valves and line
connections for firm seating, damage and
sealtightness. Check valve linkage and
fastenings (arrows) for damage and tight
ness. The length of the valve lever and
permissible angular positions on the valve
linkage are shown in the illustration below.
35
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Air levelling valve
Visual inspection
Check all component parts for wear
and damage.
1 Air bags
Check air bags for external damage (sur
face cracking, abrasion, crease
formation, trapped foreign bodies etc.).
Replace air bags in the event of damage.
Safety notice
No welding should be carried out on steel
parts of air bags and pressure vessel! The
air suspension should only be filled with
compressed air when mounted or when the
mechanical height limit has been reached!
Danger of injury!
BPW Air suspensions
Visual checks or maintenance work during the warranty period, see pages 9 11
4
36
5 Spring pivot bolts
Check bushes move vehicle backward and
forward slightly with the brake applied, or
move rolled spring ends with the aid of a
lever. No play should be present in the rolled
spring end when doing so. If the fastening is
loose the spring pivot bolt may be damaged.
Check the wear washers in the
hanger bracket.
Check the M 30 lock nut on the spring
pivot bolt for tightness.
Tightening torque with a torque wrench:
Air suspension hanger brackets
up to 07/2001 M 30 M = 750 Nm(700825 Nm)
from 08/2001 M 30 M = 900 Nm(840990 Nm)
Channel cross member
M 30 M = 900 Nm(840990 Nm)
The serviceable life of the rubber/ steel
bush is dependent on the tightness of the
inner steel bushing.
37
Singlesided lift
Twosided lift
Washer
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spring pivot bolt spring pivot bolt
Spring pivot bolt bearing
with axle lift
3 Shock absorber fastening
Check lower and upper shock absorber
fastening for tightness.
M 24 M = 420 Nm (390460 Nm)
In the case of alloy hanger bracket:
M 24 M = 320 Nm (300350 Nm)
4 Spring mounting kit
Check lock nuts of spring Ubolts for
tightness. If loose, tighten nuts alternately
a little at a time. No welding should be
performed on the trailing arm spring!
M 22 M = 550 Nm (510605 Nm)
M 24 M = 650 Nm (605715 Nm)
When mounting new spring mounting kit
components for Airlight II:
Tightening torque:
M 22 M = 550 Nm + 90 angle tightening
BPW Air suspensions
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39
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8 Check straps
Examine check straps and attachment.
Replace if necessary.
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7 Axle lift
Check the M16 lock nuts on the lever arm
fixing and diaphragm cylinder to make sure
they are tight. Tighten with a torque
wrench if necessary.
supporting arm M 16 M= 230 Nm
cylinder M 16 M= 180 210 Nm
Check for wear on the bump stop on the
lever arm or the stop for the doublesided
lift. Make sure they are secure.
M 12 M= 66 Nm
BPW Air suspensions
5
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6 Air bag fastenings
Check air bag fixing screws or nuts for
tightness.
M 12 M= 66 Nm
M 16 M= 230 Nm

BPW Air Suspension Maintenance Instructions

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