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Maintenance manual no. MM-0556
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1. ice tool into the pivot bush sleeve from the serv 11 Insert inner vice tool MST 3420 replace the pivot rito ser bushes as described in the following paragraphs 10 Using the Arvinme central tube 4 Suspension Overhaul 12 Press the Front Bush Tool FBT C against the pivot bush and 14 Attach the Rear Bush Tool RBT F to the funnel D and insert the threaded bar Fit washer and nut A to draw secure in place with the bearing cups bearing race B and nut bar and secure to FBT Fig 4 28 Fig 4 30 13 Push funnel D onto the trailing arm outer tube opposite the 15 Apply turning moment to the nut A at the bearing end FBT Recess facing towards pivot bush Fig 4 29 continue turning the nut until the pivot bush is drawn completely into the funnel D Fig 4 31 4 Suspension Overhaul 16 Dismantle the tooling and remove the pivot bush from the Pivot Bush Replacement funnel Fig 4 32 1 Apply P 80 gel solution around the pivot bush Fig 4 33 funnel Fig 4 34 and trailing arm outer tube Fig 4 35 C 17 Remove any debris that may be left from the trailing arm outer tube G MERITOR EUROFLEX 9i Suspension Range 4 Suspension Overhaul 3 Fit bush tool to trailing arm as shown Fig 4 37 2 Insert the replacement pivot bush into the funnel D and ali
2. 7 Axle amp Suspension Welding Recommendations WARNING To prevent serious eye injury always wear always wear Safe eye protection when you perform vehicle maintenance or service Incorrect weld placement will void ARVINMERITOR s warranty and can reduce the fatigue life of the trailer axle beam and suspension components Serious personal injury can result The suspension and axle must be protected from heat and weld spatter to avoid damage and any plastic or rubber components must be properly covered All parts must be dry and free from oil and dirt prior to welding Ensure that the suspension is properly earthed to avoid arcing A WARNING Incorrect weld placement or weld spatter can result in reduced fatigue life of the suspension system serious personal injury and damage to components For further information refer to the ROR Care website at www RORCare com Refer to the MERITOR EUROFLEX 9i Suspension General Assembly Drawings for further details MERITOR EUROFLEX 9i Suspension Range Maintenance Schedules pg 45 Maintenance Schedules 46 Table of Torque Values MERITOR EUROFLEX 9i Suspension Range 8 Maintenance Schedules After First 1000 KM Check all fastener torques and tighten where required according to the values in the table in this section Examine all valves and air hose joints for leaks or signs of pipe work rubbing against the chassis or suspension components Check the suspension r
3. IS IN THE RIDE HIEGHT POSITION Torque up the top and bottom damper bolts using a 36mm spanner and socket and the pivot bolts Refer to torque tables Section 8 8 Drum Brake Trailers refit the brake chambers on the air chamber brackets and secure using the original nuts if undamaged ideally new nuts and washers should be used ensure nuts and washers are clean 9 Disc Brake Trailers reconnect the brake pipes 10 Refit the clevis and split pins in the slack adjuster levers and remove the spring cages if spring brakes are fitted Check the brake adjustment as detailed in the ARVINMERITOR axle service manual 11 Refit the road wheels and lower trailer chassis and axle off their support stands MERITOR EUROFLEXTM 9i Suspension Range G MERITOR EUROFLEX 9i Suspension Range Alignment Tracking 39 Before you Align Axle pg 39 Front Axle pg 39 Rear Axle MERITOR EUROFLEXTM 9i Suspension Range 6 Axle Alignment This section provides details of how to re align suspensions if their settings are changed due to other work All MERITOR EUROFLEX 9i models are available with the patented pivot eye tracking facility This is re usable and does not require welding and offers 7 mm of fore and aft movement It is recommended that tracking is performed before painting and that no debris is left in the clamped faces of the joint Before you align the Axle 1 The trailer must be on a level surface and
4. shown in Fig 4 18 Bush Alignment Front Arm Orientation Top Mount T Marked Boss Low Mount X L Marked Boss MERITOR EUROFLEXTM 9i Suspension Range 4 Suspension Overhaul A Nut B Cup amp Bearing C FBT Front Bush Tool D Funnel E Inner Sleeve F RBT Rear Bush Tool G Threaded Bar H Washer Trailing Arm Fig 4 19 A WARNING Check pivot bushings for looseness and wear Replace worn or damaged pivot bushings Worn bushings can loosen and cause the trailer to wander during operation Serious injury and damage to components can result Verify that people are clear of the trailer before you inflate or deflate the air springs The air suspension has various pinch points that can cause serious personal injury Park the un laden vehicle on a flat surface and block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip or fall over Serious personal injury can result NOTE This following procedure requires the assistance of another person Before removal and fitment of pivot bushes A genuine ARVINMERITOR pivot bush replacement kit is required A pivot bush removal and insertion tool Part No MST 3420 will be required Fig 4 19 MERITOR EUROFLEX 9i Suspension Range NOTE Check the position and orientation of the original bush before rem
5. 2 i AXLE ASSEMBLY PIVOT BUSHING PIVOT BOLT ECCENTRIC ALIGNMENT BOSS WEAR WASHER PIVOT BUSH SLEEVE CONCENTRIC ALIGNMENT BOSS WASHER M24 HEX NUT M24 HANGER BRACKET i i 3 C gt O DAN FW N n2 SHOCK ABSORBER SHOCK ABSORBER BOLT UPPER WASHER M24 HEX NUT M24 SHOCK ABSORBER BOLT LOWER AIR SPRING PEDESTAL HEX NUT M12 AIR SPRING RETAINING SCREW M12 AIR SPRING WASHER M12 MERITOR EUROFLEX 9i Suspension Range 2 2 Introduction Identification Plate Details The suspension type can be determined by viewing the details in the type box A as shown Fig 2 3 Ld TYPE XXX XXXXX XXXX APPROVAL No DAUERBREMSE NA NOM CAPACITY KG V MAX COMB CAPACITY XXXX KG KM H XXX 3 MERITOR EUROFLEXTM gj Suspension Range Inspection amp Maintenance pg 15 pg 15 pg 16 pg 16 pg 17 Before entering Service Inspection Maintenance Lubrication Ride Height Adjustment MERITOR EUROFLEX 9i Suspension Range 3 Inspection amp Maintenance A CAUTION If any welding is done around the suspension and axle running gear then suitable precautions should be made to protect the running gear from weld spatter Failure to do so may result in premature failure of running gear components Ensure that we
6. Fitting New Air Spring Shock Absorber Replacement Pivot Bush Removal Pivot Bush Replacement MERITOR EUROFLEXTM 9i Suspension Range 4 Suspension Overhaul MERITOR EUROFLEX 9i Air Spring Range A WARNING Park the un laden vehicle on a flat surface and block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip or fall over Serious personal injury can result Air Spring Replacement Removal 1 Expel all air from the system Fig 4 1 2 Remove the air inlet pipe from the push to connect fitting Fig 4 2 3 Using a 19mm spanner remove the M12 nuts from the top of the air spring Figure 4 3 and the two M12 bolts and washers securing the airspring piston to the trailing arm Fig 4 4 4 Remove the complete airspring by compressing it slightly if required MERITOR EUROFLEXTM 9i Suspension Range 4 Suspension Overhaul 5 Remove the air fitting Fig 4 5 3 Align and locate the air inlet and mounting stud respectively in the slot and hole on the pedestal Fig 4 7 Fitting a New Air Spring 4 Align and locate the lower mounting bolt holes with the relevant holes in the trailing arm platform Fig 4 8 1 Fit the air fitting Fig 4 6 Fit new retaining bolts and washer and tighten to a torque of 7ONm 2 Compress the new air spring and slide into position between the trailing arm platform
7. be removed as detailed in Section 4 and replacement of the bush and possibly the wear plates is advised Failure to do so may result in tyre wear or structural damage Check all fastener torques and tighten where required according to the values in the table in this section If an axle lift assembly is fitted ensure it is operating correctly Check the extra air springs if fitted are operating as the axle is being raised For detailed information refer to the Arvinmeritor Lift Axle manual Check arms and welds for cracks in all inspection intervals stated Every 100 000 KM Check the dampers for oil leaks along their body Lever between the damper eye ends top and bottom and close bracketry to ensure no excessive lateral movement exists indicating bush failure or loose bolts Check the airsprings for air leaks and signs of damage especially to the rubber bellows Details of replacing them can be found in Section 4 Uncouple the levelling valve arm axle rubber joint and raise and lower the arm to check that the valve is passing air in and out of the suspension system 8 Maintenance Schedules Check the pressure protection valve by draining the brake and suspension air tanks and couple up an air pressure gauge to each tank With an air supply of 6 5 bar recharge the tanks The brake tank pressure should reach 5 5 bar minimum before the suspension tank begins to charge Clean under the suspension inside the hanger brackets an
8. it cannot be activated inadvertently Never use compressed air to remove dust or for the purpose of drying Any type of dust can be injurous to health if inhaled e When the servicing has been completed it is essential that you road test the vehicle Access Information on ArvinMeritor s Web Site Additional maintenance and service information for ArvinMeritor s commercial vehicle systems component lineup is also available at www meritorhvs com To access information go to Products amp Services Icon from drop down menu click on Literature on Demand The screen will display an index of publications by type 1 General Information ARVINMERITOR Suspension Warranty MERITOR EUROFLEX 9i Air Suspension supplied in kits covered for 24 MONTHS PARTS AND LABOUR MERITOR EUROFLEX 9i Air Suspension units assembled with an Axle by ArvinMeritor 36 MONTHS PARTS AND LABOUR MERITOR EUROFLEX 9i Front and Rear Arms welded by ArvinMeritor are covered for a further 2 years PARTS ONLY For full warranty terms and conditions see ARVINMERITOR Warranty Terms and Conditions Unless otherwise stated Aftermarket components are warranted for 1 year parts only mechanical failure only Warranty Procedure Should any ARVINMERITOR equipment fitted to your trailer become unserviceable within the warranty period contact the trailer manufacturer or ARVINMERITOR Service Department who will advise on the appropriate action A comprehensive net
9. the ride height with the wheels on See Axle Alignment Section 6 and refer to the Ride Height Adjustment details Section 3 12 Refit the shock absorber Do not torque the Shock absorber nuts to final torque until the axle is aligned and the trailer is at the ride height with the wheels on See Axle Alignment Section 6 and refer to the Ride Height Adjustment details Section 3 13 Refit the wheel s where applicable pressurise the air springs and set ride height 14 Torque all nuts and bolts to final tightening torque Refer to Section 8 for torque specification table MERITOR EUROFLEXTM 9i Suspension Range Removal amp Replacement pg 35 Axle Removal pg 36 Axle Replacement MERITOR EUROFLEXTM 9i Suspension Range 5 Axle Removal amp Replacement NOTE The MERITOR EUROFLEX 9i suspension is an integrated axle and suspension module The suspension cannot be removed from the axle Any attempt to do so will seriously damage the axle and suspension and will invalidate the ArvinMeritor warranty Removal 1 Ensure no air is left in the system 2 If spring brakes are fitted they should be released and constrained using a caging tool 3a Drum Brake Trailers Remove the split pins and clevis pins securing the brake chambers to the slack adjuster levers 3b Disc Brake Trailers Remove the brake pipes leaving the chamber attached to the calliper 4 If the axle is used to locate the bottom arm
10. volumes of air are not constantly bled off during normal suspension travel but still allowing a relatively quick reaction to an increase in load or when the trailer is being brought up to operating height from flat Determining the correct ride height Measure ride height from the top of the axle to the bottom of the chassis rail See diagram Fig 3 1 and chart Fig 3 2 for setting dimensions This can be found on the axle 1 0 plate or contact ARVINMERITORs Technical Sales Department qe 0 Vehicle Chassis No DIM Y DIM X Ride Height Model Bush Alignment Damper Pt No 1 272 136 5 200 Lowmount L 21228392 2 297 161 5 225 Lowmount L 21228392 3 322 186 5 250 Lowmount L 21228392 4 347 211 5 275 Lowmount L 21228392 5 372 236 5 300 Lowmount L 21228392 6 397 261 5 325 Lowmount L 21228392 7 422 286 5 350 Lowmount L 21228392 8 447 311 5 375 Lowmount L 21228392 9 272 261 5 325 Topmount T 21228930 10 297 286 5 350 Topmount T 21228930 11 322 311 5 375 Topmount T 21228930 12 347 336 5 400 Topmount T 21228930 13 372 361 5 425 Topmount T 21228930 14 397 386 5 450 Topmount T 21228930 15 422 411 5 475 Topmount T 21228930 16 447 436 5 500 Topmount T 21228930 MERITOR EUROFLEXTM 9i Suspension Range MERITOR EUROFLEXTM 9i Suspension Range Suspension Overhaul pg 21 pg 22 pg 24 pg 27 pg 31 Air Spring Removal
11. with the suspension height control valve remove the eye coupling on the levelling valve arm from the pin on the axle Figure 5 1 MERITOR EUROFLEXTM 9i Suspension Range 5 Jack up the trailer and support it under the chassis to take the weight of the axle to be removed 6 Support the axle to be removed on stands such that a pump trolley or similar device can be slid between them lower the axle once it is unbolted from the suspension 7 Remove the wheels from the axle 8 Using a 36 mm spanner and socket remove the nut and washer from the lower damper bolt and withdraw the bolt Slacken the top damper bolt nut and pivot the damper upwards to clear the axle and secure it to the chassis 9 If required remove the airspring as detailed in Section 3 For single axle trailers and rear axles of tandems and tri axles proceed as follows 10 Using a 36 mm spanner and socket slacken the two main pivot bolt nuts just enough to allow the arms to easily pivot 11 Slide trolley jacks as required under the axle jack them up to take the weight of the stands Remove the stand and lower the jacks Pull the axle clear backwards and clear of the trailer For the front axle of a tandem and the centre or the front axle on a triaxles trailer proceed as follows 12 Using a 36 mm spanner and socket remove the two main pivot nuts and washers and remove the bolts ensure the arms are supported to prevent them dropping 13 Slide troll
12. 2 MERITOR an ArvinMeritor brand Maintenance manual no MM 0556 Trailer Air Suspension System MERITOR EUROFLEX 9i Range Issue October 2009 Contents pg 4 pg 5 pg 6 pg 8 pg 9 pg 9 pg 10 pg 11 pg 12 pg 13 pg 14 pg 15 pg 15 pg 16 pg 16 pg 17 pg 20 pg 21 pg 22 pg 24 pg 27 pg 31 pg 34 pg 35 pg 36 Section 1 General Information Safety Instructions Warranty Section 2 Introduction Description Principle of Operation Ancilliary Equipment Important Suspension Parameters Exploded view amp Parts List ID Plate Section 3 Inspection amp Maintenance Procedures Before entering Service Inspection Maintenance Lubrication Ride Height Adjustment Section 4 Suspension Overhaul Air Spring Removal Fitting New Air Spring Shock Absorber Replacement Pivot Bush Removal Pivot Bush Replacement Section 5 Axle Removal amp Replacement Axle Removal Axle Replacement pg 38 pg 39 pg 39 pg 39 pg 42 pg 43 pg 44 pg 45 pg 46 pg 48 pg 49 pg 49 pg 49 pg 49 pg 50 pg 50 Section 6 Axle Alignment Tracking Before you Align Axle Front Axle Rear Axle Section 7 Axle amp Suspension Welding Recommendations Axle amp Suspension Welding Recommendations Section 8 Maintenance Schedules Maintenance Schedules Table of Torque Values Section 9 Fault Finding amp Diagnostics Braking Problems Tyre Wear Excessiv
13. EXTM 9i Suspension Range 9 Fault Finding amp Diagnostics Condition Possible Cause Recommended Action Vehicle body incorrect ride height during operation Insufficient air pressure to the suspension system Check air compressor and pressure protection valve for proper operation Inspect system for leaks Repair and replace as necessary Main air pressure drops to 6 5 Bar 1 Ruptured air spring Inspect air springs and replace as necessary 2 Leaking air lines Insperct air lines and repair or replace as necessary Hard Ride 1 Improper ride height or air springs flat Check and adjust ride height See first condition Suspension ride height not maintained during operation 1 Clogged air filters Inspect and clean or replace as necessary 2 Moisture in air tank Drain air tank and evacute air system of moisture 3 Clogged filter screens in height control valve Inspect and clean or replace as necessary 4 Damaged linkage or incorrect valve mounting Replace repair or adjust as necessary Incorrect tyre clearance in full bounce 1 Incorrect tyre size Replace tires with the recommended tyre size Trailer not pulling straight dog walk 1 Trailer axles out of alignment Realign axles 2 Loose alignment bosses or pivot bolt Align axles and tighten pivot bolts to the correct torque Trailer wandering or unusual rattl
14. and the sir spring pedestal MERITOR EUROFLEX 9i Suspension Range 22 4 Suspension Overhaul 5 Fit new nuts to the upper mounting studs and tighten to a 7 Pressurise the air system Fig 4 11 torque of 41Nm Fig 4 9 6 Connect the airline Fig 4 10 A CAUTION The air spring and connecting pipes must be free from interference or obstruction by tyres metal components etc Damage to components through abrasion will result in premature failure 8 Check that tyres metal components etc do not interfere with the air spring particularly the rubber components 9 Check all disturbed connections for air leaks 10 Raise the trailer and remove the safety stands 11 Verify that the ride height of the trailer is correct Refer to the trailer OEM s specification for the correct ride height Adjust accordingly following the procedure detailed in the Section 3 Ride Height Adjustment MERITOR EUROFLEX 9j Suspension Range 4 Suspension Overhaul A WARNING Verify that people are clear of the trailer before you inflate or deflate the air springs The air suspension has various pinch points that can cause serious personal injury Park the un laden vehicle on a flat surface and block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip or fall over Serious personal injury can result Check Shock bushings for loo
15. axle to the centerline of the rear axle measurements AR and AL 2 To obtain correct alignment the dimensions must be within 3mm at both ends of the axle Figs 6 2 and 6 3 If Adjustment is required Proceed to step 3 below If Adjustment is not required Proceed to step 4 NOTE Before you align an axle ensure the pivot bolt is free to move in the adjustment slot 6 Axle Alignment 3 Using a 36 mm spanner and suitable wrench loosen the pivot bolts on both sides Place 36 mm spanner on an outboard boss eccentric boss Fig 6 1 and rotate in desired direction to give an equal measurement on either of the axle to the kingpin NOTE Align the axle so that measurement AR equals measurement AL within 3 mm Figs 6 2 and 6 3 Repeat the procedure on the other pivot bolt if required 4 When the axle is aligned correctly tighten the pivot bolts to 800 Nm 5 Refit the road wheels 6 Charge the system with air 7 Apply the parking brake 8 Remove the chassis stands 9 Reinflate the suspension AR AL 3mm LR LL 4 2mm DR DL 1 5mm 0 90 1 5 Fig 6 2 MERITOR EUROFLEX 9i Suspension Range 6 Axle Alignment AL 3mm BR BL 3mm LR LL 2mm DR DL 1 5mm 0 90 1 6 MERITOR EUROFLEXTM 9i Suspension Range Axle amp Suspension Welding Recommendations pg 43 Axle amp Suspension Welding Recommendations MERITOR EUROFLEXTM 9i Suspension Range
16. could also cause the airspring sidewalls to become contracted and result in damage These instances can be avoided by using an anti vacuum system 6 CHECK STRAPS amp QUICK EXHAUST VALVES All applications that involve a sudden removal of load e g HukePak must have a check strap on each axle or quick exhaust valves fitted A CAUTION Failure to adhere to this may result in serious damage to the suspension and may invalidate the ArvinMeritor warranty MERITOR EUROFLEX 9i Suspension Range 2 Introduction Fig 2 1 Important Suspension Parameters A RIDE HEIGHT This is the distance from the centre of the axle to the underside of the chassis B FRAME BRACKET HEIGHT C AIRSPRING PEDESTAL HEIGHT D PIVOT TO AXLE CENTRE LINE This is the distance from the pivot centre in the frame bracket to the centre of the axle tube E AXLE CENTRE TO AIRSPRING CENTRE LINE This is the distance from the axle tube centre to the centre of the airspring pedestal Both dimension D and E must be measured when the axle is in the ride height position and dimension A is set MERITOR EUROFLEX 9i Suspension Range F AXLE CENTRE LINE TO PIVOT BUSH CENTRE HEIGHT NOTE Refer to ARVINMERITOR installation drawings CD or contact ARVINMERITOR Technical Sales Department for allowable options and recommendations 2 Introduction Exploded View MERITOR EUROFLEXTM 9i Suspension Assembly Fig 2
17. d around the trailing arm pivots Check between the wear plates on the inside faces of the hanger brackets and the trailing arms for signs of excessive wear or damage to the rubber pivot bushes All torques must be within 5 of stated values Check arms and welds for cracks in all inspection intervals stated A WARNING Check fastener torque values tighten loose fasteners and replace damaged fasteners Loose damaged or missing fasteners can cause loss of vehicle control death serious personal injury and damage to components ap Table of Torques Fasteners Fastener Description Torque Nm 5 Pivot Nut 800 Shock Absorber Nut Top amp Bottom 500 Upper Air spring nut M12 41 Lower Air spring Screw M12 70 Do not torque the Pivot Nut Shock Absorber nuts to final torque until the axle is aligned and the trailer is at the ride height with the wheels on Refer to Axle Alignment Section 6 Figs 6 2 amp 6 3 and Ride Height Adjustment Section 3 MERITOR EUROFLEX 9i Suspension Range MERITOR EUROFLEXTM 9i Suspension Range Fault Finding amp Diagnostics pg 49 pg 49 pg 49 pg 49 pg 50 pg 50 Braking Problems Tyre Wear Excessive Roll Suspension Related Problems Axle Lift Problems Fault Diagnostic Table MERITOR EUROFLEX 9i Suspension Range 9 Fault Finding amp Diagnostics This Section 15 intended to give guide to the trailer operator to enable him to assess prob
18. d all procedures and instructions before you begin to service or repair a unit Some procedures require the use of special tools and lubricants for safe and correct service Failure to use special tools when required can cause series personal injury to service personnel as well as damage to equipment and components ARVINMERITOR uses the following notations to warn the user of possible safety issues and to provide information that will prevent damage to equipment and components A WARNING A Warning indicates you must follow a procedure exactly Otherwise serious Personal injury can occur NOTE A NOTE indicates an operation procedure or instruction that is important for correct service A NOTE can also supply Information that can help to make service quicker and easier A CAUTION A caution indicates that you must follow a procedure exactly Otherwise damage to equipment or components can occur Serious personal injury can also result in addition to damaged or malfunctioning equipment or components This symbol indicates that a you must tighten fasteners to a specific torque value G MERITOR EUROFLEX 9i Suspension Range Safety Instructions e Observe the manufacturers safety instructions for jacking up and securing the vehicle e Only use original ArvinMeritor parts Use only the tools recommended e Observe the following service instructions and notes e When working on the suspension assembly you must ensure that
19. e Roll Suspension Related Problems Axle Lift Problems Fault Diagnostic Table MERITOR EUROFLEX gisuspension Range All rights reserved No part of this publication may be reproduced in any form or by any means or granted to any third parties without the written permission of ARVINMERITOR ARVINMERITOR reserves the right to publish revisions at any time for technical or commercial purposes Therefore all material contained in this manual is based on the latest information available at time of publication approval 2009 ArvinMeritor Inc Document No MM 0556 Edition October 2009 MERITOR EUROFLEX 9i Suspension Range General Information pg 5 Safety Instructions pg 6 X Warranty MERITOR EUROFLEXTM 9i Suspension Range 1 General Information This manual describes the correct lubrication service and installation procedures for the MERITOR EUROFLEX 9i trailer air suspension system Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability The designated trademarks are registered marks of their respective owners and ArvinMeritor and its affiliates are not commercially connected affiliated or associated with any of the owners of such marks The ArvinMeritor products presented herein are not endorsed or authorized by any of the trademark owners You must follow company procedures and understan
20. es for damage and replace if necessary Check shock absorber for oil leaks nspect shock absorber bushes for damage e Ensure ride height is set correctly Check application operation and route Ensure no axle is lifted when trailer is fully loaded Excessive Roll If trailer is rolling excessively Check pivot bolt torque is correct Check pivot bush condition Check axle and suspension trailing arms for cracks Is centre of gravity excessive Ensure ride height is set correctly e f vehicle is load sensed check that a shuttle valve is fitted to prevent cross coupling Fit if necessary Suspension Air Related Problems If suspension will not inflate Check that the levelling valve is connected to the axle Ensure the brake air reservoir pressure is more than 6 5 bar Ensure the suspension air reservoir pressure is at least 6 5 bar e Check the setting of the pressure protection valve and clean the air filter e Check the axle load is not greater than the available pressure Check all pipework and fittings for leaks using soapy water e Check the airsprings for leaks using soapy water 9 Fault Finding amp Diagnostics Check levelling valve for leakage at the exhaust port and if necessary replace valve If suspension is deflating e Check all pipework and fittings for leaks using soapy water e Check the airsprings for leaks using soapy water e Check levelling valve for leakage at the ex
21. ey jacks as required under the axle and take the axle weight Remove the axle stands and slide the axle out sideways 5 Axle Removal amp Replacement Replacement If the original axle and suspension unit is not refitted the replacement must be supplied and approved by ARVINMERITOR If in doubt contact the ARVINMERITOR Technical Sales Department for detailed recommendations 1 Lift axle onto trolley jacks and rotate to ensure it s correctly oriented 2 For single axle trailers and rear axles of tandems and triaxles Slide the axle and suspension unit sideways into position and place the arms eye ends in the position in the frame brackets 3 Align the holes in the arm bushes ENSURE NO GREASE IS ON THE THREADS Fit the bolts washers wear washers bush inner sleeves and nuts and tighten such that the arms can pivot easily Continue for all models as follows 4 Lower raise the axle and trailing arm until the hole in the lower damper bush is aligned with the location hole in the arm if the old bolts are being re used ensure they are clean especially the threads and undamaged ENSURE NO GREASE IS ON THREADS Re fit the bolts 5 Fit new nuts and washers do not tighten at this stage 6 If required re fit the air spring as detailed in Section 3 T Lower raise the axle and arms until the axle is in the ride height position see section 1 IT IS VERY IMPORTANT THAT THE DAMPER AND PIVOT BOLTS ARE FULLY TIGHTEND WHEN AXLE
22. fastener torque values tighten loose fasteners and replace damaged fasteners Loose damaged or missing fasteners can cause loss of Vehicle control serious personal injury and Damage to components 1 Inspect for broken or missing fasteners Repair or replace as needed Refer to Section 8 for correct Torque specifications 2 Inspect welds for cracks at the axle hanger bracket and suspension trailing arm 3 Inspect bushings for free play use a crow bar to check for looseness or free play Replace bushings if there are any signs of excessive vertical movement CAUTION Take care not to damage any of the suspension components A 4 Inspect the rubber bellows of the air spring for any cuts or abrasions Replace the air spring immediately if it is cut or damaged in anyway CAUTION The Air Spring surface must be free of interference or obstructions by items such as tyres loose steel and brake chambers etc Damage to components can result from abrasion 5 Check for obstructions or interference to the air spring surface that can lead to damage to the air spring Relocate and secure items such as air hoses that can contact the air spring 6 Check for leaks in the air lines at the air spring bead plate piston and mounting studs Replace air lines fittings or air springs that leak Refer to Section 4 for replacement details 7 Inspect shock absorbers for worn bushings oil leaks and dents Check that the mounting h
23. gn the pips on the pivot bush with the marked line on the funnel Fig 4 36 4 Insert inner sleeve into the pivot bush central tube 5 Press the Rear Bush Tool RBT F against the trailing arm outer tube and insert the threaded bar Fit washer and nut A to draw bar and secure to RBT 6 Push funnel D onto the trailing arm outer tube opposite the RBT F Recess facing towards outer tube Attach the FBT to the funnel D and secure in place with the bearing cups bearing race and nut 7 Rotate the funnel D so that the mark is aligned to the mark on the trailing arm Fig 4 38 8 Apply turning moment to the nut A at the bearing B end continue turning the nut until the pivot bush is drawn completely into the trailing arm outer tube The turning action will lock out when the pivot bush mates up with the RBT F 9 Back off the nut and dismantle the pivot bush tooling Check for any damage to the membrane of the pivot bush MERITOR EUROFLEXTM 9i Suspension Range 69 4 Suspension Overhaul 11 Refit the trailing arm to the hanger bracket Fig 4 40 and insert new pivot bolts 10 Insert steel inner sleeve into the pivot bush central tube Fit the replacement wear washers Y to either side of the pivot bush Fig 4 39 Do not torque the pivot nuts to final torque until the axle is aligned and the trailer is at
24. h the trailer in its normal ride height un laden using a 36 mm socket and ring spanner remove the nuts and washers from the upper and lower damper bolts Fig 4 13 MERITOR EUROFLEX 9i Suspension Range 2 Withdraw the lower mounting bolt Fig 4 14 NOTE On certain applications it may be necessary to remove the brake chamber to provide clearance for lower shock absorber mounting bolt removal For brake chamber removal instructions refer to the appropriate Arvinmeritor brake service manual 3 Remove the damper from the upper mounting bolt Fig 4 15 NOTE It is not possible to remove the upper mounting bolt with the road wheels fitted to the trailer 4 Suspension Overhaul Replacement 1 Locate the top eye of the damper on to the upper mounting bolt Fit a new nut and washer Fig 4 16 2 Rotate the damper and slowly pull it to extend its length until the lower eye aligns with the mounting hole in the trailing arm Fit the lower mounting bolt flat washer and new nut Ensure the bolt head is inboard 3 Using a 36mm socket and ring spanner torque the two nuts to 500 Nm Fig 4 17 NOTE Ensure suspension is at the ride height setting before fully tightening to torque Pivot Bush A CAUTION Ensure the pips on the replacement Pivot Bush are in line with the correct alignment boss either T TOP mount or L LOW mount and the steel plates A are aligned front and rear not top and bottom as
25. haust port and if necessary replace the valve Axle Lift Related Problems If lift will not operate Work through check procedure for main suspension airsprings not inflating Check that the lift valve is correctly installed and piped Replace valve if faulty For detailed information refer to the Arvinmeritor Lift Axle manual Fault Diagnostic Table Condition Possible Cause Recommended Action All air springs flat 1 Insufficient air pressure to Build air pressure to 6 5 Bar or suspension air springs more Check compressor for correct function Check all air lines and fittings for leaks 2 Defective pressure protection Check and replace valve if valve necessary 3 Height control valve supply or Inspect height control valve supply delivery fitting clogged amp delivery fittings for restrictions 4 Air leak in system Inspect entire system for leaks Repair orreplace as necessary 5 Suspension overloaded Review load to suspension rated Capacity Air springs fully raised but do not 1 Height control valve delivery port or Inspect port for restrictions Repair exhaust exhaust port plugged or replace as necessary 2 Height control linkage broken Replace linkage Vehicle body incorrect ride height during 1 Height control valve not adjusted Inspect and adjust as necessary operation properly 2 Height control lever bent or Straighten or replace lever broken MERITOR EUROFL
26. hing with interleaf shims for improved fore aft stiffness Small diameter air spring for improved packaging Nominal ride height of 200 500mm with 200mm of total travel 100mm jounce and 100mm rebound nominal MERITOR EUROFLEX 9i Suspension Range Principle of Operation During normal running in a straight line striking bumps potholes etc superb ride characteristics are obtained due to the airsprings providing a very low vertical suspension stiffness at the wheel This ensures very little shock is transmitted to the chassis payload thus minimising structural damage or problems with goods During cornering manoeuvres the axle tube acts as an anti roll bar and links each trailing arm The majority of the compliance in roll comes from the multi functional pivot bush Careful design of the damper characteristics and positioning ensures a high degree of damping required to gain the best possible performance from an air suspension Modern dynamic analysis methods and testing were used to determine such characteristics and positions Product Compatibilities The MERITOR EUROFLEX 9i Suspension is compatible with the following brake sizes Disc Brakes ELSA 195 D ELSA 2 E ELSA 225L J D ELSA 2 E 120 OFFSET ELSA 225L J 120 OFFSET Drum Brakes ZMX QMX Q BMX ACMX For further information visit www RORCare com 2 Introduction Ancillary Equipment 1 AXLE LIFT FACILITY A choice of axle
27. ide height as explained in Section 3 Inspect the dampers for evidence of oil leaks If an axle lift is fitted check that it is functioning correctly Check the operation of all optional equipment and test for air leaks on air system equipment Individual service manuals should be referred to if required Check arms and welds for cracks in all inspection intervals stated After First 10000 KM amp Subsequent 10 000 KM Intervals Inspect the dampers for evidence of oil leaks and inspect the damper bushes for signs of rubber extrusion or damage Check the airsprings for signs of leakage and examine the rubber bellows for signs of damage from road debris or internal bump stop failure Check all pipe joints for signs of leakage and ensure that no valves are fouled with road dirt such that their operation may be impaired This is especially relevant to the levelling valve This is particularly important if the trailer has been operated in a harsh environment e g coal dust quarries etc If an axle lift is fitted check it is operating correctly MERITOR EUROFLEX 9j Suspension Range Check the operation of all optional equipment and test for air leaks on air system equipment Individual service manuals should be referred to if required Examine tyres for uneven wear If there is any present check the pivot bushes for damage and re check the axle alignment as detailed in Section 6 If damage is found then the trailing arms should
28. ing 1 Worn bushings Inspect bushings and replace as needed Broken Shock Absorbers 1 Trailer fitted with manual raise lower valve Driver forgets to set to ride height Fit auto raise lower device Driver education 2 Auto reset fitted check Check operation function of Colas EBS tractor is compatible 3 s trailer towed on sit with Check operation Dock spotter etc 4 ncorrect King pin height Set Kingpin height to recommended values from trailer plate details or contact manufacturer Air spring bump stop broken 1 Trailer driven with no air in the suspension Driver education Damage to lifter in red emergency coupling at headboard of trailer 1 Dirt in air system 2 General wear and tear Check operation Replace worn lifter in coupling 69 MERITOR EUROFLEXTM 9i Suspension Range For further information contact Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham LL12 U K Telephone 44 0 1978 852141 www arvinmeritor com www RORCare com 2009 ArvinMeritor Inc Meritor Automotive All rights Reserved Publication MM 0556 Meritor HVS Limited Commercial Vehicle Systems Grange Road Cwmbran NP44 3XU U K Telephone 44 0 1633 834 040 Descriptions and specifications were in effect at the time of this publication and are subject to change without notice or liability Meritor reserve the right to make de
29. lding earth clamps or connectors are not connected to any part of the suspension and axle running gear A WARNING To prevent serious eye injury always wear safe Eye protection when you perform vehicle maintenance or service Before Entering Service IF THE OPERATOR IS IN ANY DOUBT ABOUT THE SAFETY OF THE VEHICLE THEN IT SHOULD NOT BE OPERATED AND QUALIFIED ADVICE SHOULD BE SOUGHT Check the suspension and brake systems operate correctly Check the suspension air system for leaks by charging the system with air and testing all joints and fittings using soapy water Ensure the suspension ride height is correctly set by referring to the Ride Height Adjustment details in Section 2 If an axle lift system is fitted operate the lift system to check it operates correctly and observe the extra lift cylinders attached to the levelling valve arms to ensure they function Carry out a visual inspection of all suspension and brake system pipe work to ensure no possibility of fouling or rubbing against each other or other components Check the brake system operates correctly Check the operation of all optional equipment fitted If any doubt or problems arise refer to the appropriate service manual or seek qualified advice Gs MERITOR EUROFLEX 9i Suspension Range Inspection A WARNING Check fastener torque values tighten loose fasteners and replace damaged or missing fasteners Loose damaged or missing fasteners can cause l
30. lems The range of problems and suggested causes and cures are by no means complete but are intended to provide a solution to the most commonly encountered difficulties NOTE IF THE OPERATOR IS IN DOUBT ABOUT THE SAFETY OF THE VEHICLE HE SHOULD NOT OPERATE IT AND SHOULD IMMEDIATELY SEEK QUALIFIED ADVICE FROM ARVINMERITOR How to use this section The faults are listed under five main headings namely 1 BRAKING PROBLEMS 2 TYRE WEAR 3 EXCESSIVE ROLL 4 SUSPENSION AIR RELATED PROBLEMS 5 AXLE LIFT RELATED PROBLEMS Listed under each of these headings are the likely specific problems each followed by a check procedure which should highlight the cause of the problem If the problem cannot be solved after working through the relevant check list then further information should be obtained from ARVINMERITOR Braking Problems If brakes are not functioning correctly e Check that there is at least 6 5 bar at coupling head and the correct ratio of air is delivered to the brake chamber Check slack adjusters are correctly adjusted Ensure all brake system valves are functioning correctly IF PROBLEM PERSISTS SEE ARVINMERITOR AXLE AND BRAKE SERVICE MANUALS FOR FULL BRAKE SERVICE PROCEDURE OR SEE WWW RORCare COM MERITOR EUROFLEXTM 9j Suspension Range Tyre Wear If tyre wear is excessive Check axle alignment is correct e Check wheels are parallel i e zero camber and toe in out nspect the trailing arm pivot bush
31. lift facilities are available to fit the MERITOR EUROFLEX 9i suspension all of which are capable of being retrofitted 2 AIRSPRING DUMP FACILITY ARVINMERITOR recommends that all air suspended trailers without raise lower valves are fitted with this facility When an air suspended trailer deflates it can roll forward causing bending and possible collapse of the landing legs This is caused by wheel rotation as the axle travels up A good solution to this problem is to fit rocking type landing legs 3 RAISE LOWER FEATURE If a raise lower feature is installed on the trailer the vehicle must not be driven off with the suspension in the raised or lowered position A height limitation valve must me fitted with this feature NOTE Serious damage can occur to the suspension if the trailer is driven in the raised lowered position and doing so may void the ArvinMeritor warranty 4 AUTO DROP ARVINMERITOR recommends the fitment of this system to remove potential damage to the tyres and running gear from drivers not resetting the manual system before moving 5 ANTI VACUUM SYSTEM Ferry companies require that air suspended trailers are fully exhausted before trailers are loaded aboard ship Consequently there is risk that during loading the rubber side walls of the airspring can become trapped between the internal rubber bump stop and piston and become damaged Applications that involve a rapid removal of the load e g HuckePak
32. llowing procedure should be used Lengthen or shorten the linkage rods which connect the levelling valve arm to the axle giving a proportional increase or decrease in the ride height by slackening the two screws that pinch the rubber eye ends onto the drop bar and pulling the bar in or out of the rubber If there is insufficient adjustment i e the bar is in danger of coming out of the rubber then further adjustment can be gained by slackening the bolts holding the levelling valve to the bracket and repositioning the valve within the holes Bending of the levelling valve actuating arm is not recommended If the ride height is found to be above the recommended setting the height should first be dropped below the required setting and then increased back to the nominal ride height thus avoiding the dead band in the actuating stroke of the valve This can be done by shortening the linkage rod and bleeding air from the suspension by slackening the air pressure connection on top of the airsprings This method also applies to situations where the ride has accidentally been taken above the recommended setting NOTE Some care is needed when checking the ride height as a false reading may be obtained after tipping a load etc The levelling valve emits and exhausts air very slowly so time should be allowed for it to react once adjusted 3 Inspection amp Maintenance The valve emits air slightly faster than it exhausts This is so that large
33. oles have not become enlarged 8 Inspect the structure of the suspension including Hanger Brackets Trailing arm Shock absorber mountings Axle welds Brake interference cam or chamber Hanger bracket bracing where fitted Alignment Bosses Fasteners A WARNING Verify that people are clear of the trailer before you inflate or deflate the air springs The air suspension has various pinch points that can cause serious personal injury CAUTION Do not add lubrication or cleaning solvents to the air system These additives can contaminate the air system and damage fittings Damage to components will result 9 Inspect the height control valve for air leaks and cracked lever arm housing If air leaks or cracks are detected replace the height control valve Lubrication The EUROFLEX 9i range of suspensions does not require lubrication only lubrication is required when installing replacement pivot bushes NOTE Only use lubricant supplied in the service kit when fitting new pivot bushes MERITOR EUROFLEXTM 9i Suspension Range 3 Inspection amp Maintenance Ride Height Adjustment WARNING Overall trailer height must not exceed recommended limits for territories of application for the vehicle to clear bridge underpasses during operation Serious personal injury and damage to components will result This is an area that is probably most unfamiliar to the trailer operator and the one that will cause most
34. oss of vehicle control death serious personal injury and damage to components Inspect air Suspension components height control valve and axle at regular intervals during normal operation and each time the trailer is serviced Before each trip Visually inspect the suspension system and listen for any leaks Perform the following inspections after the first 1600 km 1000 miles of operation and at normal service intervals or annually thereafter as a minimum 1 Check fastener torque values tighten loose fasteners and replace damaged or missing fasteners 2 Inspect all upper and lower air spring and damper nuts and bolts for looseness and movement Tighten any loose nuts and bolts to the correct torque value as specified in Section 8 Thereafter inspect the suspension components each time the trailer is serviced or as specified above 3 Inspect all height control valve nuts polts linkage for looseness and movement Tighten any loose nuts and bolts to the correct torque value as specified in Section 8 Thereafter inspect the suspension components each time the trailer is serviced or as specified above 4 Inspect Pivot bolts for looseness and movement Align Track the axle before tightening any loose nuts and bolts to the correct torque value as specified in Section 8 Thereafter inspect the suspension components each time the trailer is serviced or as specified above 3 Inspection amp Maintenance WARNING Check
35. oving Fig 4 18 This will provide a guideline when fitting a new bush Pivot Bush Removal 1 Lower the landing gear 2 Support the REAR of the trailer frame 3 Set the parking brake 4 Exhaust air pressure from the suspension air springs 5 Support the axle and remove the wheel s to access the pivot bolts NOTE Although It is not necessary to remove the road wheels when replacing the pivot bushes on SINGLE wheel axle configurations the procedure may be easier with the wheels removed 6 Remove the bottom shock absorber bolts from both hanger brackets This will allow the trailing arm to articulate down when the pivot bolts are removed 4 Suspension Overhaul 7 Remove the pivot bolts and alignment bosses from the hanger bracket Figs 4 20 amp 4 21 A WARNING Ensure that the axle support is secure during this operation as the arcuate motion may cause the axle to move backwards Fig 4 22 8 Carefully rotate the trailing arm until clear of the hanger bracket Fig 4 23 and Fig 4 24 DO NOT lever off the brake chamber as shown Fig 4 25 MERITOR EUROFLEX 9i Suspension Range 4 Suspension Overhaul gt eh SS S A Y WA sleeves from the d the steel inner e e wash Figs 4 26 amp 4 27 CD CS c i D gt D R th 9 p CD CD N h 5 tb e L gt
36. problems if the following parameters are not adhered to Too high a ride height can cause more roll motion too low means that there will be loss of axle travel contacting bump stop during arduous use Parameters for setting ride height 1 The trailer should be on level ground 2 It should preferably be connected to the tractor unit to be used and in a straight line with the unit or set at the correct kingpin height Refer to chassis identification plate or contact manufacturer 3 All the trailer brakes should be off 4 There should be an air supply of at least 6 5 bar 9 The trailer should be unladen 6 If the trailer has been running it should be given at least 10 minutes to settle down re The valve should be set on increasing height as there is a dead band in the actuating stroke of the valve MERITOR EUROFLEX 9i Suspension Range 8 The ride height must be set on the axle that has the levelling valve 9 If the trailer is fitted with a lift axle this should be in the down position Once an initial setting of the ride height has been made it should be checked by measuring from the top of the axle tube to the underside of the trailer frame and comparing with the nominal ride height less 63 5mm tube radius Figs 3 1 amp 3 2 The nominal ride height is specified by the trailer builder and is shown on the axle or chassis identification plates If the ride height is found to require resetting the fo
37. rts List ID Plate MERITOR EUROFLEX 9i Suspension Range 2 Introduction Description The MERITOR EUROFLEX 9i range of air suspension system is based on a semi trailing arm suspension arrangement The trailing arms are mounted onto the axle parallel to one another and perpendicular to the axle The front of the trailing arm consists of a pivot bushing hanger bracket and alignment bosses while the rear of the trailing arm supports the air spring Figs 2 2 and 2 3 The axle is attached to the trailing arms via a welding process that can only be performed by ARVINMERITOR The trailing arms contain a multi functional pivot bush at the eye ends specially designed to accommodate vertical inputs but remaining stiff for the fore and aft inputs The trailing arms are mounted to hanger brackets which are then welded to the chassis Ride height is a very important measurement for overall vehicle height The ride height of the suspension unit is determined from the centerline of the axle to the under side of the vehicle chassis Fig 2 1 Note Ensure that ride height is set correctly If ride height is incorrect this may result in damage to suspension components and affect the trailers performance Refer to the Trailer Manufacturers recommendations for ride height setting on tractor fifth wheel Features Shock absorber with integral check strap 9 amp 11 Tonne capacity designed for trailers and semi trailers Multi functional bus
38. seness and wear Replace worn or damaged bushes or shock absorbers Worn or damaged shock absorbers can lead to reduced ride and handling performance of the trailer Shock Absorber Replacement ArvinMeritor shock absorbers incorporate an integral check strap feature However where the trailer may be subject to a sudden removal of load e g HukePak axle check straps must be fitted CAUTION Failure to adhere to this may result in serious damage to the suspension and may invalidate the ArvinMeritor warranty MERITOR EUROFLEX 9i Shock Absorber NOTE Ensure that when replacing Shock absorbers the correct size of Shock absorber is fitted to Lowmount or Topmount suspension installations Lowmount Shock Absorber 21228392 Topmount Shock Absorber 21228930 NOTE The protective shroud A on the shock absorber must not be removed Fig 4 12 Shock absorbers must be fitted in the correct orientation Current shock absorbers incorporate an adhesive label with the word TOP to indicate the correct orientation Fig 4 12 NOTE Early level shock absorbers have an adhesive label attached indicating the bottom of the shock absorber CAUTION If shock absorbers are fitted in the wrong orientaion there will be a loss of any suspension damping causing severe damage to the vehicle MERITOR EUROFLEX 9i Suspension Range 4 Suspension Overhaul Removal Identify the specific shock absorber that is damaged or leaking 1 Wit
39. sign improvements change or discontinue parts at any time ArvinMeritor
40. un laden 2 Adjust the trailer landing gear The height of the king pin should be the same as when the trailer is connected 3 Support the chassis on suitable axle stands 4 Expel all air from the system 5 Remove the road wheels Front Axle 1 Verify that the suspension is at the correct ride height Refer to Ride Height Adjustment Section 3 2 Measure from the king pin to each end of the first axle measurement DR and DL To obtain correct alignment settings Figs 6 2 amp 6 3 NOTE Rotate the hub backwards and forwards to ensure that the measurement is the maximum possible If Adjustment is required Proceed to step 3 below If Adjustment is not required Proceed to Rear Axle in this section NOTE Before you align an axle ensure the pivot bolt is free to move in the adjustment slot MERITOR EUROFLEXTM 9j Suspension Range 3 Using a 36 mm spanner and suitable wrench loosen the pivot bolts on both sides Place 36 mm spanner on an outboard boss eccentric boss Fig 6 1 and rotate in desired direction to give an equal measurement on either of the axle to the kingpin NOTE To obtain correct alignment the dimensions DR and DL must be within 3mm at both ends of the axle Figs 6 2 amp 6 3 Repeat the procedure on the other pivot bolt if required When the desired measurements have been achieved tighten pivot bolts to 800 Nm Rear Axle 1 Check the dimension from the centerline of the front
41. work of original parts distributors and service stations operate throughout Europe this is supported internationally with agents strategically placed around the world ARVINMERITOR H V S reserves the right to make changes in specifications shown herein or add improvements at any time without notice or obligation Patents and applications of MERITOR HEAVY VEHICLE SYSTEMS Ltd that is specifically relevant to air suspension systems GB Patent No GB2367111 EU Patent No EP1315918 US Patent No US7252298 GB Patent No GB2396140 GB Patent No GB2257670 US Patent No 057360774 Patents applied for EPO EP030780387 EP050257631 EP060252792 EP050254903 USA 0510 538816 US11 446 455 US10 916127 US11 875139 China 9 CN061083548 Poland PL20030376676 PARTS SHOWN ARE MADE FROM DRAWINGS IN WHICH COPYRIGHT SUBSISTS THE MAKING OF COPIES OF ANY OF THESE PARTS IS PROHIBITED ROR MERITOR ARVINMERITOR AND INDAIR ARE ALL REGISTERED TRADE MARKS IN THE UK AND ELSEWHERE The high quality assurance management systems applied by ARVINMERITOR are endorsed with the awarding of ISO 9001 Lloyd s Register Quality Assurance 2009 ArvinMeritor Inc EUROFLEX 9i Suspension Range MERITOR EUROFLEX gj Suspension Range Introduction 9 9 pg 9 pg 10 pg 11 pg 12 pg 13 Description Principle of Operation Ancilliary Equipment Important Suspension Parameters Exploded view amp Pa
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