Unit 626 Kilshane Ave, North West Business Park, Ballycoolin, Dublin 15, Ireland Telephone: +Fax: +email:sales@driverite.iol.ie
Fiat Ducato, Peugeot boxer, Citroen Jumper W21-760-2207
INSTALLATION INSTRUCTIONS
All work should be carried out in a properly equipped workshop with due regard to Health and Safety Regulations. No further reference to Health and Safety Regulations will be made, but they must be considered at all times. The kit should be opened and the contents checked against the parts list provided. Identify the various components and familiarise yourself with them using drawings and information provided.
WARNING Do not inflate this assembly when it is unrestricted. When installed, a minimum of 10 psi should be maintained in the air bellows at all times to avoid any possible damage. Do not inflate beyond 100 psi. IMPORTANT This kit is not designed to increase the GVW of your vehicle. For your safety and to prevent possible damage to your vehicle, do not exceed the maximum load recommended by the Vehicle Manufacturer.

Parts List

Description
255 Air Spring Upper Bracket Lower Bracket Bracket Strap 3/8 x 4 Poly Conv Tubing 3/8-16 x 6 Carriage Bolt M10 x 1.25 x 30 Hex Head 3/8 Lock Washer 3/8 Flat Washer

Quantity

3/8-16 Flange Lock Nut 3/8-16 Nylon Insert Nut Thermal Sleeve Cable Ties Inflation Valve Metal Valve Cap 3/8-16UNC x 1 Hex Head Elbow NPT to Tee Piece

Tubing and Parts

Bracket set

Air bellows

1. PREPARATION:
This suspension kit consists of all parts necessary to make a successful installation onto your Vehicle. All parts have been tested thoroughly. Please make sure you take all necessary safety precautions while fitting the kit. Note: you should first read these instructions carefully and then take all parts out of the box and pre-assemble them as far as possible before fitting them onto your vehicle.

2. INSTALLATION

Pre-assemble the air bellows as shown in the diagram on the left. Turn Air Fitting away from the two threaded studs. Place the two 10 x 150 bolts into the drilled holes on the lower bracket. Now bolt the base of the Air Bellow to the Lower Bracket using the 3/8-16 UNC hex head bolts Place one of the bracket straps under the lower bracket. Position the lower bracket in such a way that it stands parallel to the axle.
Fasten the upper bracket to the framework using M10 x 30 bolts. Ensure the two flanges of the Upper Bracket are pushing away from the inside of the chassis as shown.
Now take the pre-mounted Air Bellow/Bracket assembly, squeeze the Bags together (for ease of installation) and place each assembly in the centre of the axle. Bolt the Bellows to the Upper Bracket.
The lower bracket now rests loosely on the axle. The actual attachment of the Lower Bracket is made with one additional Bracket Strap under the axle. Use the M10 lock nuts to fasten to axle.
The position of the lower bracket must take place in such a way that it stands parallel to the axle. Place thermal sleeves over the air lines for protection. See Diagram.
LSV - Model type 230 After the assembly of the air bellows the LSV must be pre-loaded to increase the automatic Load Sensing. The original bracket must be exchanged by a longer bracket, which is included in the kit. The position of this bracket must be made in such a way that the distance between the upper and the lower points as shown amounts to 155 mm. See Photograph. LSV - Model type 244 After the assembly of the Air Bellows the LSV must be pre-loaded to increase the automatic Load Sensing. The LSV clamp must be shifted 25mm toward the end of the rod as shown. In order to achieve this, the clamping screws (Fig 1) must be loosened and moved 25 mm towards rod end.

TORQUE SETTINGS:

(valid for the most usual mobile travel vehicles)
Wheel bolts: Motor vehicle type: Fiat Ducato 10/14 Fiat Ducato Maxi Mercedes Sprinter Wheel bolt M14 x 1,5 M16 x 1,5 M14 x 1,5 Torque Settings 160 Nm* 180 Nm* 180 Nm*

Heart pin (centering bolt) 8,8 * M 8 M 10 M 12 U bolts: M 8 M10 M12 M14 Shock absorber: Fiat Ducato MB Sprinter 208-316 8.8 10.9 MB Sprinter 408-Nm* above 80 Nm 25 Nm* 47 Nm* 118 Nm* 130 Nm* 25 Nm 47 Nm 86 Nm
below 70 Nm Screws 110 Nm Screws

above 140 Nm

below 140 Nm
* manufacturer data * DIN 13, sheet 33 shank end screws quality 8,8, coefficient of friction m = 0,14

TO AVOID LEAKAGES:

The Suspension is inflated with compressed air via nylon hoses with an outside diameter of . The connections are called Plug-in connections. This kind of connection allows you to attach the air hose without a tool. Here the hose must be put so far into the connection, until it locks. The correct fit can be examined by easily pulling on the hose. To recognize if it is the correct fit, during pulling the hose, the ring of the connection moves along with the hose. For the loosening of the hose connector the hose must be pushed toward the Plug in connection. Subsequently, with the ring held, the hose can be taken off. Note: With the pulling to check if the ring is too far pulled out, a leakage can occur! Note: In order to avoid slow air losses, the nylon hose should be cut straight with a sharp blade. Do not use a side cutter.
Correctly cut. Straight cut off.

Wrong.

With frequent assembly use a nylontubing cutter.

Air fittings:

All air fittings are supplied with an easy push to connect fitting. To prevent leaking of air though, make sure that all tubing is cut squarely. These fittings make it easy to fit the air tubing and also to replace it if necessary.

Brittle:

Like all flexible rubber construction units, a certain natural embitterment occurs with the air bag. This procedure is natural, since the softeners in the plastic evaporate. If this occurs, then this leads to a cracking at the surface layer of the bag. If the auxiliary pneumatic spring is driven with a wrong operating pressure the embitterment is increased.

Air loss/leakage:

If within 24 hours the air pressure drops more than 0.2 bar a leak may be on the kit. If this is the case, then the complete kit must be sprayed with soap solution (leak detection spray). The leak is detected on the basis that bubbles appear. Most frequently the bubbles will be seen at the junction points after initial assembly. Mostly the reason for this is because of the non right-angled cut of hoses. As previously stated cutting off should take place by means of a straight cutter and not with the side cutter!

When driving on a ferry or when driving through a large bump on the road the possibility exists that at short notice the kit will be hit with a higher filling pressure (maximum 8 bar) than the vehicle is permitted to drive. Therefore, depending upon motor vehicle type and loading, the rear of the vehicle rises. This measure must be cancelled again however during normal travel, since this affects the braking action of your vehicle. If one drives on a high air pressure, then the brake delay of your vehicle can be reduced. Always guarantee that while driving the maximum operating pressure is kept in accordance with partial appraisals or registration papers.