Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 1 of 9

I 060101 Internal: X Customer: X Supplier:

General This assembly information is an integral part of our terms of sale and delivery. We shall be compelled to reject any guarantee claims in the event of non-observance of these guidelines. The axle loads stated are not to be exceeded. Centre of gravity heights and information on the assembly drawings are to be observed. The design is to take into account the fact that in a semitrailer the vertical load on tractor must be stabilised via the fifth wheel of the traction unit. Attention is to be paid to sufficient clearance for the tyres and axle components in the case of lowered vehicles.

Construction description GIGANT air suspension units can be used as single-axle or multi-axle units. The parabolic trailing arms assume the entire guiding forces of the axle. The braking moment is also taken up via the trailing arms. The U-shaped arrangement of trailing arms and the axle form a stabiliser which stabilises the vehicle and counteracts the rolling moment with transverse acceleration. The guiding forces which are taken up by the springs are transmitted at the horizontal level exclusively via the air suspension brackets in the vehicle chassis. The vertical forces are also supported via the air bellows as well as via the air suspension brackets. The chassis supports are to have suitable diagonal members to take up the forces which occur in the vehicle chassis. No guarantee can be assumed in the event of any damage in the case of insufficient support.

Attachment of the air suspension brackets General Due to their narrow design, the GIGANT air suspension brackets for spring width 70 are suitable for welding onto the narrow chassis beams in modern vehicle constructions. Important note: • The welding equipment clamping contact may not be attached to the axle components in order to prevent bearing damage. • Welding and attachment of the clamping contact to the radius arm is not permitted. • Trailing arms are to be protected during welding from contact with welding beads, electrodes and welding tongs (notch effect)

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 2 of 9

I 060101 Internal: X Customer: X Supplier:

Welding sequence The stipulation for the welding sequence is that no tack seams or welding seam starts are permitted within 50mm of the corner edges of the air suspension brackets. Welded seams (proposal GIGANT a4 according to DIN 1912) are to be produced according to quality category B of DIN EN ISO 5817.

Standard suspension bracket

50

50

50

Suspension bracket with C-prifil

Side support It is necessary to brace the air suspension brackets at the sides in order to provide an appropriate abutment for the shear forces. This side brace is to be supported by a transverse frame in the chassis in order to introduce the forces into the vehicle chassis equally. When using a C-Profile type front bracket assembly, no additional side support is needed. Appropriate torsion-tolerant but rigid bracing of the air suspension brackets is to be observed in the case of torsion-tolerant vehicle chassis (e.g. flatbed trucks)

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 3 of 9

I 060101 Internal: X Customer: X Supplier:

In the case of torsion-resistant vehicle chassis, the bracing for the sir suspension brackets may be correspondingly rigid (e.g. tank trucks, silo trucks and vans). We always recommend open profiles e.g. U-profiles. Torsion-resistant, closed profiles are to be avoided in the transverse frame (hazard of cracking at the welded joins). The cross bracing may only be effected in the area stated in order not to restrict the function of other attachments.

The data and instructions stated here may only be regarded as proposals since the bracing and dimensioning depend on the type of vehicle and its conditions of use. This data is only known to the vehicle producer and is to be taken into consideration by the producer in the construction.

Positional tolerances The bracket position must conform to certain tolerances to ensure subsequent assembly of the axle with the mounted spring. Position of the brackets longitudinally to the direction of travel: A line through the four hole centre points in the air suspension brackets should form the base of an isosceles triangle. The intersecting point of the two sides should be at the traction point of the vehicle. These sides should not exceed a deviation from the equilaterality of ± 2 mm. If this tolerance is greater then only a reduced tracking quality can be achieved at subsequent tracking adjustment of the vehicle. For parallelism, the centre lines of the long holes in the air suspension brackets of the other axle centre lines, is guaranteed by the adherence to the tolerance by ±1 mm. Position of the brackets crosswise to the direction of travel: The distance of the brackets should not exceed an accuracy of ± 1 mm. Otherwise the subsequent mounting of the axle with the mounted spring would be at risk. The axes through the centre point of the long holes of the respective bracket are to have concentricity to the second bracket of an axle assembly of 1mm.

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 4 of 9

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Surface protection Application of a state-of-the-art surface coating is always necessary for the bracket; this coating is to protect the material from weathering. The bracket is supplied with a temporary surface protection. In coating the brackets, attention is to be paid that the film thickness at the areas in contact with components is a maximum of 30µm. These include the contact surfaces of the eccentric bush, the silent block and the shock absorbers. Contact surfaces of the shock absorber

Contact surfaces of the silent block

Contact surfaces of the eccentric bush

Bellows mounting General handling The roll bellows are a high-quality product made of resistant materials. These materials give the bellows some unusual properties for use in the commercial vehicle sector. However these materials have some restrictions. These include paying attention during mounting that the roll bellows are protected from welding spatters and excess heat.

Assembly Assembly is effected on the prepared vehicle chassis. The dimensions for the attachment of the bellows can be seen in the installation drawing for the air suspension set. The drill holes are to conform to DIN ISO 273 on average. The distance of the holes is to be produced according to DIN ISO 2768m. The design of the flanged plate takes the bearing capacity of the chassis support into consideration in order to conform to the state of the art. Thus no guarantee can be assumed for damage to the bellows due to incorrect bracing of the bellows. A maximum projection of the flanged plate over a rigid abutment is to be observed. The flanged plate may only project over the edge of the abutment by 85mm (recheck). However, in total 40% of the circumference of the flanged plate edge must still be supported by the abutment. W1

max.85

W1 + W2 = max. 220°

W2

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 5 of 9

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Use Compressed air is applied to the air bellows for use in commercial vehicles. This compressed air is to be free from foreign substances, in particular such substances as may cause sustained damage to the air bellows. Guarantee claims may only be enforced if the vehicle is fitted with in-line filters in the compressed air supply lines and signal lines.

Leakproofness The air bellows are subject to constant production fluctuations arising from the production process sequences. These inevitably lead to tolerances with regard to dimensions, technical function as well as impact on leakproofness. It is normal for air bellows to lose a slight amount of air. The limit which may escape for new bellows is assumed as 0.5 bar within 24 hours at an initial pressure of 2 bar. The bellows are regarded as leakproof as long as this value is maintained as a minimum.

Axle set assembly Subassembly An axle set comprises the axle with mounted air suspension springs and also the brake cylinder on request. This subassembly is assembled on a mounting device. This permits mounting of the axle set without problem if the tolerances in the Section “Positional tolerances for the air suspension brackets” are observed. This assembly in the device ensures that the dimensional tolerances required are observed. spring track

track

Subassembly mounting Before the eyes can be fitted into the air suspension bracket, the strike washer must be pushed onto the protruding silent block bush. The strike washers are designed to fit tightly on the silent block and are wedged there. The strike washer serves as a cardanic movement stop for the spring eye. This provides the vehicle with reliable performance. The strike washer also serves as a wearing disc and can be replaced if required.

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 6 of 9

I 060101 Internal: X Customer: X Supplier:

Once the four strike washers have been pushed onto the silent block bushes, the axle can be fitted into the air suspension brackets with the springs. The air suspension bolts can then be pushed through the bracket and the silent block with a mounted eccentric bush from the outside. The second eccentric bush is positioned on the opposite side and fixed with a security nut. Attention must be paid before tightening the security nut that the circular marking on the eccentric bush points to the ground when the vehicle is upright.

Track adjustment The spring bolt is to be tightened with 200Nm in this position. Using an open-ended spanner AF 60, the axle with eccentric bush can now be moved lengthwise and the track adjusted. Attention – you have to look for that the both eccentric bushes of one air suspension bracket are in the same angle position and that the marking points are exactly opposite each other. Centring tool 00311045 is recommended in this case. Once the track has been adjusted, the security nut is tightened with the tightening procedure stated. The torque-torsion angle method is to be applied to exclude outside influences; this method specifies a torque of 400Nm with a subsequent torsion angle of 90°. This represents a torque of 1300Nm direction of travel

1 maximum axle displacement forward

2 maximum axle displacement backwards

check marking point

Bellows mounting When mounting air bellows without piston bottom plate, attention must be paid to the seat of the piston in the recessed groove of the spring end. As soon as the piston securely grips in the groove, the nut on the tie rod can be tightened with the torque stated. The instructions for fitting the bellow with piston bottom on the spring can be seen in the installation drawing for the air suspension set.

Ride height controller There is a drilled plate welded to the axle centre for the attachment of the ride height controller; the rods of the controller can be attached to this plate. We refer to the manufacturer’s documentation for the adjustment of the controller. The control system of the controller must ensure that the air feed to the air bellows is closed at the maximum lifting height of the air suspension unit. The dimension for the maximum lifting height can be seen in the unit drawing.

Assembly guidelines for air suspension units with spring width 70

Issue date: 09.02.2007 Drafted: 17.01.2006 Index: 4 Page: 7 of 9

I 060101 Internal: X Customer: X Supplier:

Ride height restriction In certain applications such as tipper or container chassis, we specify the use of arrester wire which restricts rapid upward movement of the air suspension unit in the case of sudden unloading of the vehicle and protects the chassis from mechanical damage. The use of quick-action ventilating valves with ventilating control is possible under certain preconditions, only with the approval of GIGANT.

Brake cylinder If no brake cylinder has been fitted by us, then only brake cylinders which conform to the brake specifications and approval guidelines of the caliper manufacturer may be used.

Axle lift General The axle lift is a device to lift an axle in multi-axle vehicles. The loading capacity of a multi-axle unit is not completely utilised when the vehicle is empty or partly loaded. In this case, the air bellows of the axle to be lifted are ventilated and the axle is lifted using the axle lift. There is no tyre wear on this axle in operating status and operating costs are minimised. As soon as the vehicle is fully loaded, the bellows pressure in the remaining air bellows increases. This increase in pressure is converted in the axle lift; the lifted axle is lowered and the corresponding air bellows are aerated. For the reliable operation of the axle lift device, the purity of the compressed air must be such that the membrane-type cylinder does not sustain any damage nor should its function be restricted.

Fitting The axle lift is suspended in the bracket after track adjustment and is secured with the clamping bolt. Attention is to be paid that the selected ride height data of the axle lift matches the air suspension unit data. The pre-mounted axle lift is inserted, with the vehicle lowered, with its two sides along the side panels of the air suspension bracket, between the damper mounting tube and the eccentric bush. In this process, the clamping bolt, without nut, is inserted using the other hand in the direction of the long hole in the air suspension bracket.