Meritor Air Suspension Service Manual
Contents
1. soso or de 2995 Con calle som 4 The high guality assurance management systems applied by MERITOR are endorsed with the awarding of ISO 9001 Lloyd s Register Quality Assurance ArvinMeritor brand Air Suspension Service Identifying the Suspension Type Suspensions leaving the MERITOR factory are fitted with an optional identification plate which contains all the information needed to ensure the correct replacement parts are obtained Flexair Suspension TYPE FL11 425 T APPROVAL No RDW19940707 SERIAL No E999999 G94 0000 an ArvinMeritor brand NOM CAPACITY 11000 CAPACITY KG WREXHAM LL12 OPB UK ASSEMBLED IN THE EEC The suspension type code includes the suspension model ride height and tracking type as shown below L Low Height Integrated Cross Member Dual Height S z Self Steer FL Flexair NB Special Lightweight Command Steer XL Flexlite D z Demount 9 9000 11 11000 Ride Height T Tracking Fitted 9L 9000L 11L 11000L See Page 8 e g 425 9NB 9000NB 11L 11000L 150 9M 9000M 11D 11000D 9HL 9000HL 11B 11000B 9i 9000i 11LB 11000LB 9H 9000H The models of suspension are detailed in Section 1 of this manual Identifying the Serial Number NOTE The serial number is also carried by the axle and thus contains the brake lining code This will be missing if a suspension is sold separately Brak2. 3 Place the trailing arm 11 in position under the frame bracket and lift the eye end into position and align the holes 4 Ensure that pivot bolt 3 is clean and undamaged especially if the original bolt is to be refitted and apply a thin coat of grease to the shank ENSURE NO GREASE IS LEFT ON THE THREADS 5 Fit the bolts and new nuts 5 and washers 4 and tighten not fully at this stage such that the arms can still rotate easily 6 Ensure that the mating faces between the spring seat 10 U bolt plate 19 and arm are clean and locate the arm in the seat ensuring spacer plates are in position 7 Clean the U bolt threads 9 and ensure they are not damaged and fit the bolts U bolt plates and new nuts 17 and washers 18 Nip the nuts up but do not fully tighten 8 Refit the base of the airspring 22 as detailed in section 3 9 Check that the lower damper bolt 16 is clean and un damaged apply a thin coat of general purpose grease ENSURE NO GREASE IS LEFT ON THE THREADS Align the bolt with the hole in the spring seat U bolt plate and fit the bolt and a new nut 13 and washer 14 e an ArvinMeritor brand 10 Lift lower the axle until it is in its ride height position see section 1 and support 11 Re track the axle as detailed in section 2 12 Tighten the bolt nuts in a diagonal sequence Refer to torque tables on Page 29 13 Tighten the pivot bolt Refer to
3. Check shock absorbers for oil leaks Inspect shock absorber bushes for damage Ensure U bolts are correctly torqued Ensure ride height is set correctly ArvinMeritor brand If 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 Check the setting of the pressure protection valve and Clean the air filter Check the axle load is not greater than the available pressure Check all pipework and fittings for leaks using soapy water Check the airsprings for leaks using soapy water Check levelling valve for leakage at the exhaust port and if necessary replace valve If suspension is deflating Check all pipework and fittings for leaks using soapy water Check the airsprings for leaks using soapy water Check levelling valve for leakage at the exhaust 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 If main suspension airsprings fail to deflate when lift is operated Check the H
4. AL 3mm BR BL 3mm LR LL 2mm DR DL 1 5mm 0 590 10 With a standard semi trailer the measurements are to the kingpin With a drawbar trailer they should be to the A frame towing eye Before the measurements are made the A frame eye must be in its central position to the chassis as shown in Fig 2 ArvinMeritor brand Air Suspension Service AR AL 3mm LR LL 2mm DR DL 1 5mm 0 90 10 RE FITTING SUSPENSIONS It is recommended that if any doubt exists on the correct method of fitting removal of the frame brackets and pedestals of a suspension advice should be obtained from the MERITOR Engineering A CD of installation drawings is available from Meritor Air Suspension Service FLEXAIR 9000 o o Optional tracking see section 2 Air Suspension Service FLEXAIR 9000L Optional tracking see section 2 Air Suspension Service FLEXAIR 9000M Optional tracking see section 2 Air Suspension Service FLEXLITE XL9000 Air Suspension Service FLEXAIR 11000 Optional tracking see section 2 Air Suspension Service FLEXAIR 11000L Optional tracking see section 2 Air Suspension Service SECTION 3 General Maintenance Ref Figs 4 5 6 7
5. FL11000L 200 250mm 11000 kg 900 1200mm 0 95mm 110 110mm Yes Yes No Dual Side Lift 0 FL11000LB Ride Height Capacity Frame Centres min max Airspring Offset Axle Travel up down Off road suitable Suitable for drum Suitable for disc Recommended axle lift Pivot Eye Tracking o option s standard 500 725mm 11000 kg 900 1200mm 0 95mm 95 100mm Yes Yes Yes Dual Side Lift 0 225 450mm 11000 kg 900 1200 0 95 95 100 Yes Yes Yes Dual Side Lift 0 FL11000 150 150mm 9000 kg 900 1200 0 95mm 65 110mm No Yes No fy an ArvinMeritor brand FL11000D 225 450mm 11000 kg 900 1200mm 0 95 70 200 Yes Yes Yes Dual Side Lift 0 Ride height restrictions appy Can be reduced with restriction Contact Meritor HVS for details Air Suspension Service SECTION 2 Re aligning and Re fitting of Suspensions This section provides details of how to re align suspensions if their settings are changed due to other work It also discusses how to re fit a suspension should the case arise RE ALIGNMENT TRACKING All Flexair models are available when new with an optional patented pivot eye tracking facility This device once used during the trailer build is welded up and cannot be used for re tracking Flexlite models feature as standard a pivot eye tracking facility which is re usable non welded If no tracking device is fitted the facility at th
6. and air hose joints for leaks or signs of pipework rubbing against the chassis or suspension components Check the suspension ride height as explained in section 8 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 AFTER FIRST 10000 KM AND 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 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 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 2 ArvinMeritor brand damage is found then the
7. trailing arms should be removed as detailed in section 6 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 torgues and tighten where reguired 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 lift cylinders are operating as the axle is being raised 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 If the bushes are damaged they should be replaced Check the airsprings for air leaks and signs of damage especially to the rubber bellows Details of replacing them can be found in section 3 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 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 bar minimum before the suspension tank begins to charge Clean under the suspension inside the hanger brackets and around the trailing arm pivots Check between the wear plates welded to the inside faces of the hanger bra
8. with an automatic reset facility triggered by application of the brakes Upon the first brake application after using the raise lower system an electrical signal is sent to the levelride unit that automatically resets the trailer to its normal ride height This system eliminates unnecessary damage to the suspension that can occur if the trailer is driven in the raised or lowered position 5 AUTO DROP When a lift axle is fitted it is possible to fit a Meritor ELMS system that enables the lift axle to automatically drop to its unlifted position when the axle load exceeds a predetermined level 6 ANTI VACUUM SYSTEM A requirement by Ferry companies is that air suspension systems are 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 This can be avoided by using an anti vacuum system available from MERITOR A special quick release valve is fitted to each side of the suspension which allows air into the system from atmosphere when the airspring pressure falls below atmospheric pressure thus preventing the sidewalls from collapsing Meritor Patents All MERITOR designs are registered and copyright exists on all drawings In some instances these designs are covered by one or more patents The following patents apply to the designs shown in this manual GB 2237
9. 780 GB 2257670 GB 2165 501 ArvinMeritor brand Air Suspension Service RIDE HEIGHT FRAME BRACKET HEIGHT C AIRSPRING PEDESTAL HEIGHT D PIVOT TO AXLE CENTRE LINE E AXLE CENTRE TO AIRSRING CENTRE LINE FL9000HL FL9000NB FL9000HLL an ArvinMeritor brand Air Suspension Service A RIDE HEIGHT FRAME BRACKET HEIGHT AIRSPRING PEDESTAL HEIGHT D PIVOT TO AXLE CENTRE LINE E AXLE CENTRE TO AIRSRING CENTRE LINE FL11000L FL11000L 150 XL9000HL FL11000D ArvinMeritor brand Air Suspension Service RIDE HEIGHT FRAME BRACKET HEIGHT C AIRSPRING PEDESTAL HEIGHT PIVOT TO AXLE CENTRE LINE E AXLE CENTRE TO AIRSRING CENTRE LINE FL11000B FL11000LB IMPORTANT SUSPENSION PARAMETE
10. RQUED UP EVENLY 12 Lower raise the axle and trailing arm until the hole in the lower damper bush is aligned with the location hole in the seat U bolt plate If the old damper bolts 16 are being re used ensure they are clean especially the threads and undamaged and apply a thin coat of general purpose grease to the shank of the damper bolts ENSURE NO GREASE IS ON THREADS Re fit the bolts 13 Fit new nuts 13 and washers 14 and nip up 14 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 ONLY FULLY TIGHTENED WHEN THE AXLE IS IN THE RIDE HEIGHT POSITION Torque up the top and bottom damper bolts using a 36mm spanner and socket and the pivot bolts using a 46mm spanner and socket Refer to torque tables on Page 29 Air Suspension Service 15 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 15 DISC BRAKE TRAILERS Reconnect the brake pipes 16 Refit the clevis and split pins in the slack adjuster levers and remove spring cages if spring brakes are fitted Check the brake adjustment as detailed in the MERITOR axle service manual 17 Refit the road wheels and lower trailer chassis and axle off their support stands 6 an ArvinMeritor brand Air Suspension Servic
11. RS 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 NOTE Refer to MERITOR installation drawings CD for allowable options and recommendations Air Suspension Service Flexair FL9000 Range Summary Ride Height Capacity Frame Centres min max Airspring Offset Axle Travel up down Off road suitable Suitable for drum Suitable for disc Recommended axle lift Pivot Eye Tracking o option s standard OPTION FL9000 375 550mm 9000 kg 1150 1400mm 30mm 100 110mm Yes Yes Yes Cradle Dual Side Lift 0 FL9000HL FL9000L 200 375mm 9000 kg 1150 1400mm 30mm 100 95 Yes Yes No Cradle Dual Side Lift 0 FL9000HLL FL9000NB 310 425mm 9000 kg 1150 1400mm 30mm 80 90 110mm No Yes Yes Cradle 0 FL9000i an ArvinMeritor brand FL9000H 500 550mm 9000 kg 1150 1400mm 30mm 100 110mm Yes Yes Yes Cradle Dual Side Lift 0 FL9000M Ride Height Capacity Frame Centres min max Airspring Off
12. amp 8 Removal and Refitting of Airsprings REMOVAL 1 Ensure no air is in system 2 Jack up chassis and support on stands Flexair 9000 90001 and Flexlite 3 Using 27mm spanner remove the M22 air inlet and the securing nut 26 and washer 27 from the top of the airspring 4 Using a 19mm spanner remove the M12 nut 24 and washer 23 from the top of the airspring and the two M12 bolts 20 and washers 21 securing the airspring piston to the trailing arm 5 Remove the complete airspring by compressing it slightly if reguired Flexair 11000 and 11000L 6 Using a 27mm spanner remove the M22 air inlet pipe from the top of the airspring 7 Using a 19mm spanner remove the four M12 nuts 24 and washers 23 from the top of the airspring 8 Using a 24mm socket remove the two M16 nuts 31 and washers 30 securing the airspring and offset plate 29 to the trailing arm and remove the airspring by compressing it slightly if reguired 9 Using a 19mm socket remove the four M12 bolts 20 and washers 21 securing the offset plate 29 to the airspring piston ArvinMeritor brand REPLACEMENT Flexair 9000 9000L and Flexlite 1 With the airspring compressed fit in position on the airspring pedestal and fit the 22 nut 26 and washer 27 and new M12 nut 24 and washer 23 and nip tight 2 Pull the piston down and align the two required holes with the holes in the trailing arms Fit the t
13. an ArvinMeritor brand Meritor Manual ICC ir Suspension Serv Flexlite XL9000 Flexair FL9000 amp FL11000 A E ie ES E lt Air Suspension Service FLEXAIR FL9000M FLELITE XL9000 FLEXAIR FL11000 Air Suspension Service INDEX Section 10 Description THE MERITOR WARRANTY THE SUSPENSION I D PLATE INTRODUCTION TRACKING AND RE ALIGNMENT REPLACEMENT OF AIRSPRINGS REPLACEMENT DAMPERS REPLACEMENT OF AXLE REPLACEMENT OF TRAILING ARMS REPLACEMENT OF PIVOT BUSHES SETTING OF HEIGHT VALVE MAINTENANCE SCHEDULE FAULT FINDING an ArvinMeritor brand Page 12 21 22 23 25 26 27 28 30 Air Suspension Service Meritor HVS Suspension Warranty 1 MECHANICAL FLEXAIR AND INDAIR SUSPENSIONS 24 MONTHS PARTS AND LABOUR 2 FLEXAIR AND FLEXLITE UNITS ASSEMBLED WITH AXLE BY H V S 36 MONTHS PARTS AND LABOUR For full warranty terms and conditions see Meritor Warranty Terms and Conditions Publication No 4 84 1 Unless otherwise stated Aftermarket components are warranted for 1 year parts only mechanical failure only ArvinMeritor brand Warranty Procedure Should any MERITOR equipment fitted to your trailer become unserviceable within the warranty period contact the trailer manufacturer or MERITOR Service Department who will advise on the appropriate action A comprehensive network of original parts distributors and service s
14. ckets 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 Air Suspension Service Data Tables and Charts A TABLE TORQUES ON FLEXAIR FASTENERS NOTE All suspensions to be at ride height before fastener torques are applied FL9000M suspension must be set at the maximum ride height before any torques are applied 2 2 2 Torgue Fastener Description Nm Ib ft Main pivot nuts M30 1100 810 Main pivot nuts M24 800 585 U bolts and centre lift M24 680 500 Damper bolts M24 500 370 Trailing arm centre bolts M16 230 170 Bottom airspring support plate studs M16 180 135 Top airspring fixing nuts M12 70 50 Airspring piston fixing bolts M12 70 50 Axle lift nut M10 36 27 B TABLE OF TORQUES ON FLEXLITE FASTENERS NOTE All suspensions to be at ride height before fastener torques are applied Torque Fastener Description Nm Ibf ft Main pivot nuts M24 800 585 U bolt nuts M24 800 585 Damper nuts M16 300 220 Bottom airspring screws M12 70 50 Top airspring fixing nuts M22 60 45 Top airspring fixing nuts M12 70 50 ArvinMeritor brand Air Suspension Service SECTION 10 Flexair Fault Finding This section is intended to give a guide to the trailer operator to enable him to assess problems The range of problems and suggested causes and cures are by no mea
15. ct kingpin height 3 All the trailer brakes should be off 4 There should be an air supply of at least 6 5 bar 5 The trailer should preferably be unladen or the load evenly distributed laterally across the trailer 6 If the trailer has been running it should be given at least 10 minutes to settle down 7 The valve should be set on increasing height as there is a dead band in the actuating stroke of the valve 8 The ride height must be set on the axle which has the levelling valve 9 If the trailer is fitted with a lift axle this should be in the down position Levelling Valve Arm Slacken screws to adjust height Connecting Linkage The ride height is the distance between the centre line of the axle and underside of the frame Subtracting 63 5mm half the axle tube diameter from the ride height gives a simple checking dimension from the underside of the frame to the top of the axle tube 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 The nominal ride height is specified by the ArvinMeritor brand trailer builder and is shown on the axle and suspension 1 0 plates If the ride height is found to reguire resetting the following procedure should be followed Lengthen shorten the linkage rods which connec
16. dquarters 2135 West Maple Road Troy Michigan 48084 U S A Telephone 1 248 435 1000 ArvinMeritor Commercial Vehicle Aftermarket AG Neugutstrasse 89 8600 D bendorf Switzerland Telephone 41 0 1 824 8200 Fax 41 0 1 824 8264 ArvinMeritor Commercial Vehicle Systems Postbus 255 5700AG Helmond Churchilllaan 204A 5705BK Helmond Holland Telephone 31 0 492 535805 Fax 31 0 492 547175 ArvinMeritor South Africa Commercial Vehicle Systems Telephone 27 0 83 602 1603 Descriptions and specifications were in effect at the time of publication and are subject to change without notice or liability Meritor reserve the right to make design improvements change or discontinue parts at any time ArvinMeritor
17. e SECTION 6 Removal and Replacement of Trailing Arms Flexair and Flexlite Models REMOVAL 1 Ensure no air is in the system 2 Jack up the trailer chassis and place support stands in a suitably safe location 3 Support the axle and remove the road wheel off the axle side from which the arm is to be removed This allows access to the U bolts 9 4 Using a 36mm 24mm for XL spanner and socket remove the nut 13 and washer 14 from the lower damper bolt nut 16 and withdraw the bolt Slacken the top damper bolt nut 7 and pivot the damper upwards to clear the axle and secure it to the chassis 5 Using a 36mm 24mm for XL socket remove the four U bolt nuts 17 and washers 18 and withdraw the U bolts Remove the U bolt plate 19 6 Un fasten the base of the airspring 22 as detailed in section 3 7 Using a 46mm 30mm for XL spanner and socket remove the pivot bolt nut 5 and washer 4 and withdraw the pivot bolt 3 Care must be taken to support the trailing arm 11 during this operation since it may immediately drop down from the frame bracket 1 The arm can now be removed REFITTING 1 Ensure that the inner faces of the frame bracket wear washers 28 are tacked to the frame bracket and are clean and undamaged Apply a coating of grease to all faces and bores 2 Check that the bore in the trailing arm bush 12 is clean and apply a thin coating of general purpose grease
18. e Lining Type Build Month Seguential Number Order Number Build Year NOMINAL CAPACITY This is the capacity of the suspension before being matched to an axle COMBINED CAPACITY This is the suspension capacity in use and will reflect the axle capacity and any other constraints Air Suspension Service SECTION 1 Introduction Meritor air suspensions are specifically designed to suit the MERITOR range of axles Modern technology and stringent testing have been used to ensure the perfect match The basic design of these units is of the flexible link trailing arm type The axle is mounted to flexible trailing arms using a cast steel seat design The arms are then mounted via rubber bushes to a pair of hanger brackets which are then welded to the chassis At the rear of each trailing arm an airspring is located and the top of the airspring fitted to the chassis 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 stifiness 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 flexing of the trailing arms Thus their design is a very careful mi
19. e spring seat must be used The facility at the seat allows 8mm of movement by loosening the U bolts To carry out this operation proceed as follows 1 With the trailer unladen and no air in the system support the chassis on stands 2 Remove the wheels 3 If the U bolts 9 are not loose unfasten them enough to enable the axle to slide on the trailing arm and slide it as far rearward as possible 4 Using a tape measure place one end on the side of the hub flange and measure to the king pin Rotate the hub forward and backwards to ensure that the measurement is the maximum possible 5 Slide the axle on each trailing arm until the measurements from each hub to the kingpin DR amp DL are equal to within 2mm as shown in Fig 1 6 When correct remove each U bolt nut 17 and washer 18 shown in fig 3 and clean the bolt thread to remove dirt in turn Fit a new nut and washer Repeat the operation with all nuts Tighten all nuts in a diagonal sequence With new U bolts see table on page 29 If existing U bolts are used re torgue Flexair and Flexlite to 425 Ibf ft 575 Nm 7 Replace wheels and remove supports from chassis If a drawbar unit is being worked upon the procedure is the same except the tracking measurements are to a different point an ArvinMeritor brand ArvinMeritor brand Air Suspension Service AR
20. ingle axle trailers and rear axles of tandems and triaxles slide the axle into position over under the rear of the suspension unit For the front axle of a tandem and the centre or front axle on a triaxle trailer 3 Slide the axle sideways into position and place the trailing arms eye ends in position in the frame brackets 1 4 Align the holes in the trailing arm bushes 12 apply a thin coat of general purpose grease to the shank of the pivot bolts 3 ENSURE NO GREASE IS ON THREADS Fit the bolts and new washers 4 and nuts 5 and tighten such that the arms can easily pivot Continue for all models as follows 5 Position axle stands under the axle at a workable height and lower the axle onto them ensuring the trailing arm 11 is above below as reguired 6 Ensure the mating faces on the trailing arm 11 seat 10 and U bolt plate 19 are clean and undamaged 7 Lift lower the trailing arm to the axle and locate into the spring seats 8 Fit the U bolts 9 top plates 19 and new U bolt nuts 17 and washers 18 and nip up 9 Refit the airspring piston to the trailing arm as described in section 3 10 Re track the suspension as detailed in section 2 11 Torque up the U bolts using a 36mm socket in a diagonal sequence With new U bolts see table on page 29 If existing U bolts are used re torgue Flexair and Flexlite to 425 Ibf ft 575 Nm IT IS IMPORTANT THEY ARE TO
21. nd washers 18 from each side of the suspension remove the U bolt plate 19 and withdraw the U bolts 9 For single axle trailers and rear axles of tandems and triaxles proceed as follows 11 Using a 46mm spanner and socket slacken the two main pivot bolt nuts 5 just enough to allow the trailing arms to easily pivot Swing the arms off the axle leaving it supported on the stands 12 Slide trolley jacks as required under the axle jack them up to take the weight off the stands Remove the stands and lower the jacks Pull the axle clear backwards over under the arms and clear of the trailer For the front axle of a tandem and the centre or front axle on a triaxle trailer proceed as follows 13 Using a 46mm spanner and socket remove the two main pivot nuts 5 and washers 4 and remove the bolts 3 Ensure the arms are supported to prevent them dropping The arms can now be removed 14 Slide trolley jacks as required under the axle and take the axle weight Remove the axle stands and slide the axle out sideways ArvinMeritor brand REPLACEMENT If the original axle is not to be refitted the replacement must be supplied and approved by MERITOR The use of axles previously used on other suspensions is prohibited If in doubt contact the MERITOR Engineering Applications Department for detailed recommendations 1 Lift axle onto trolley jacks and rotate to ensure it is correctly orientated 2 For s
22. ns 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 MERITOR 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 MERITOR BRAKE FAULTS If brakes are not functioning correctly Check that there is at least 6 5 bar at coupling head Check slack adjusters are correctly adjusted Ensure all brake system valves are functioning correctly IF PROBLEM PERSISTS SEE MERITOR AXLE AND BRAKE SERVICE MANUALS FOR FULL BRAKE SERVICE PROCEDURE TYRE WEAR If tyre wear is excessive Check axle alignment is correct Check wheels are parallel i e zero camber and toe in out Inspect parabolic trailing arm pivot bushes for damage and replace if necessary Check shock absorber for oil leaks Inspect shock absorber bushes for damage Ensure ride height is set correctly EXCESSIVE ROLL If trailer is rolling excessively
23. set Axle Travel up down Off road suitable Suitable for drum Suitable for disc Recommended axle lift Pivot Eye Tracking o option s standard Flexlite XL9000 Range Summary OPTION Ride Height Capacity Frame Centres min max Airspring Offset Axle Travel up down Off road suitable Suitable for drum Suitable for disc Recommended axle lift Pivot Eye Tracking o option s standard 275 375mm 9000 kg 1150 1400mm 30mm 100 110mm Yes Yes Yes Cradle Dual Side Lift 0 XL9000 375 450mm 9000 kg 1150 1400mm 30mm 100 100mm No Yes Yes 300 425 9000 kg 1150 1400mm 0 30mm 85 205mm No Yes Yes XL9000L 200 250mm 9000 kg 1150 1400mm 30mm 100 100mm No Yes No 375 425mm 9000 kg 1150 1300mm 30mm 100 110mm Yes Yes Yes Not available 0 XL9000H 475 550mm 9000 kg 1150 1400mm 30mm 100 100mm No Yes Yes 228 453mm 9000 kg 900 1200mm 0 95mm 65 230mm Yes Yes No Dual Side Lift 0 XL9000HL 250 350mm 9000 kg 1150 1400mm 30mm 100 100mm No Yes No Air Suspension Service Flexair FL11000 Range Summary OPTION Ride Height Capacity Frame Centres min max Airspring Offset Axle Travel up down Off road suitable Suitable for drum Suitable for disc Recommended axle lift Pivot Eye Tracking o option s standard OPTION FL11000 250 475mm 11000 kg 900 1200mm 0 95mm 110 110mm Yes Yes Yes Dual Side Lift 0 FL11000B
24. t of Axle There are a number of ways of removing the axle depending on how much of the suspension is to be dismantled The following procedure however is recommended assuming the suspension is to be left in place 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 3 DRUM BRAKE TRAILERS Remove the split pins and clevis pins securing the brake chambers to the slack adjuster levers 3 DISC BRAKE TRAILERS Remove brake pipes leaving the chamber attached to the caliper 4 If the axle is used to locate the bottom of the arm with the suspension height control valve remove the eye coupling on the levelling valve arm from the pin on the axle 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 to lower the axle once it is unbolted from the suspension 7 Remove the wheels from the axle 8 Using a 36mm spanner and socket remove the nut 13 and washer 14 from the lower damper bolt 16 and withdraw the bolt Slacken the top damper bolt nut 7 and pivot the damper upwards to clear the axle and secure it to the chassis 9 Remove the airspring as detailed in Section 3 10 Ensuring the axle supports are safe and using a 36mm socket remove the four U bolt nuts 17 a
25. t the levelling valve arm to the axle giving a proportional increase or decrease in the ride height by slackening the two cheesehead screws which 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 The valve emits air slightly faster than it exhausts This is so that large volumes of air are not constantly bled off during normal suspension travel but still allowing a relativel
26. tations operate throughout Europe this is supported internationally with agents strategically placed around the world MERITOR H V S reserve the right to make changes in specifications shown herein or add improvements at any time without notice or obligation PARTS SHOWN ARE MADE FROM DRAWINGS IN WHICH COPYRIGHT SUBSISTS THE MAKING OF COPIES OF ANY OF THESE PARTS IS PROHIBITED Patents and applications of MERITOR H V S Ltd that are specifically relevant to air suspension systems Indair ride height adjustment GB Patent No 2165500 Shock absorbers as restraints GB Patent No 2165501 Indair suspension GB Patent No 2165195 CA Patent No 1232302 DE Patent No 3437393 NZ Patent No 209838 US Patent No 4593930 Deflation of air suspension GB Patent No 2184405 Compact Indair GB Patent No 2194761 Load distribution on air suspended vehicles GB Patent No 2239222 EPO BE DE DK ES FR IT NL appn 90314050 AU Patent No 646005 IE appn 4530 90 NZ appn 236519 PT appn 96354 ZA Patent No 90 10241 Suspensions for vehicles long stroke EPO AT BE DE DK FR GB IT NL SE Patent No 472309 Vehicle tracking adjustment GB Patent No 2257670 Loading unloading of air suspended vehicles EPO BE DE ES FR GB IT NL appn 92307639 Axle lift GB appn 9404557 PCT EPO AT BE DE ES FR GB GR IE IT LU MC NL PT SE AU LA NZ US appn PCT GB94 458 O MERITOR HVS 2 OF
27. te the top eye of the damper and fit the mounting bolt with a flat washer under the head of the bolt and behind the nut Ensure the bolt head is inboard Fit a new nut and washer 2 Rotate the damper and slowly pull it to extend its length until the lower eye aligns with the mounting holes in the axle seat Fit the lower mounting bolt flat washers and new nut Ensure the bolt head is inboard 3 Using a 36mm socket and ring spanner torgue the two nuts to 370 Ibf ft 500 Nm Removal and Replacement of Dampers Flexlite Models REMOVAL 1 With the trailer in its normal ride height unladen using a 24mm socket and ring spanner remove the nuts 7 amp 13 and washers 6 amp 14 from the top and bottom damper bolts 2 Withdraw both the upper and lower mounting bolts 2 amp 16 with their washers 15 and remove the damper 8 REPLACEMENT 1 Locate the top eye of the damper and fit the mounting bolt with a flat washer under the head of the bolt and behind the nut Ensure the bolt head is inboard Fit a new nut and washer 2 Rotate the damper and slowly pull it to extend its length until the lower eye aligns with the mounting holes in the axle seat Fit the lower mounting bolt flat washers and new nut Ensure the bolt head is inboard 3 Using a 24mm socket and ring spanner torque the two nuts to 220 Ibf ft 300 Nm an ArvinMeritor brand Air Suspension Service SECTION 5 Removal and Replacemen
28. the torque table on page 29 14 Tighten the upper and lower damper bolts Refer to the torque table on page 29 15 Refit the wheel and lower the axle and trailer chassis off their support stands Air Suspension Service SECTION 7 Replacement of Pivot Bushes 12 1 Follow the procedure in section 6 to remove the trailing arm in guestion then proceed as follows 2 Using MERITOR service tool part number 21215793 for Flexair Models or part number 21219080 for Flexlite Models remove the old bush 3 Fit the new bush using the same service tool lubricating the rubber prior to fitting with soft soap or Applied Chemicals Ltd EP pressing lubricant grade 1 630 Ensure when fitting the bush it is inserted centrally into the spring eye end 4 Refit the trailing arm following the procedure in section 6 an ArvinMeritor brand Air Suspension Service SECTION 8 Setting Suspension Height Control Valve This is an area which is probably most unfamiliar to the trailer operator and the one which will cause most 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 corre
29. umphrey valve is correctly installed 9 I main airspring pressure is lower than available pressure replace Humphrey valves Work through check procedure for main suspension airsprings not inflating If lift is insufficient Check the extra lift cylinders are operating correctly Ensure trailer ride height is set correctly For further information contact MERITOR Air Suspension Service Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham 1112 0 UK Telephone 44 0 1978 852141 Fax 44 0 1978 856173 Meritor HVS Mitry Mory S A Commercial Vehicle Systems Z I du Moulin Vent 9 rue des Fr res Lumi re 77290 Mitry Mory France Telephone 33 0 1 64 27 44 61 Fax 33 0 1 64 27 30 45 Meritor HVS Verona s r l Commercial Vehicle Systems Via Monte Fiorino 23 37057 San Giovanni Lupatoto Verona Italy Telephone 39 045 8750399 Fax 39 045 8750640 8750513 Meritor HVS Barcelona S A Commercial Vehicle Systems Ctra Granollers Sabadell Km 13 3 Poligono Argelagues 08185 Lli de Vall Spain Telephone 34 9 3 843 95 68 Fax 34 9 3 843 83 59 For further information contact Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham LL12 U K Telephone 44 0 1978 852141 Fax 44 0 1978 856173 www arvinmeritor com Copyright 2001 Meritor Automotive All rights Reserved Publication 4 91 1 ArvinMeritor Inc World Hea
30. wo M12 bolts 20 and washers 21 and nip up 3 Torque the top M12 nut and four bottom M12 bolts to 50 Ibf ft 70 Nm and the M22 nut to 45 Ibf ft 60 Nm Flexair 11000 11000L and 9000M 4 Using a 19mm socket bolt the lower airspring support plate 29 to the airspring piston using the four M12 bolts 20 and washers 21 located with the bolt heads in the counter bores in the offset plate Torque up to 50 Ibf ft 70 Nm 5 Ensure the offset plate is rotated to give the desired air inlet position on the top of the airspring 6 With the airspring compressed fit the airspring studs in position in the airspring pedestal Fit four new M12 nuts 24 and washers 23 and nip tight 7 Pull the piston offset plate down and fit the two M16 studs 28 through the holes in the trailing arm Fit the two new nuts 31 and washers 30 and nip tight 8 Torque the M12 top nuts to 50 Ibf ft 70 Nm 9 Torque the M16 bottom nuts to 135 Ibf ft 180 Nm 10 Lower chassis off support stands NOTE USE ONLY MERITOR GENUINE SPARE PARTS Air Suspension Service SECTION 4 Removal and Replacement of Dampers Flexair Models REMOVAL 1 With the trailer in its normal ride height unladen using a 36mm socket and ring spanner remove the nuts 7 amp 13 and washers 6 amp 14 from the top and bottom damper bolts 2 Withdraw both the upper and lower mounting bolts 2 8 16 and remove the damper 8 REPLACEMENT 1 Loca
31. x of strength and stiffness 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 Ancillary Equipment 1 SUSPENSION PIPING SYSTEMS Pipework is available as complete pre assembled kits for quick and easy fitting These are available in different versions depending on the bogie specification e g tandem triaxle etc 2 AXLE LIFT FACILITY Axle lift facilities are available that will fit all suspension models They are capable of being retrofitted and in some cases not requiring any welding 3 AIRSPRING DUMP FACILITY MERITOR recommends that all air suspended trailers without raise lower valves are fitted with this facility and a kit is available from MERITOR 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 ArvinMeritor brand 4 RAISE LOWER FEATURE With air suspensions it is possible to raise or lower the chassis to facilitate loading at different dock heights MERITOR offers the Levelride II system to facilitate this requirement This is an MERITOR patented system that is a raise lower device but
32. y quick reaction to an increase in load or when the trailer is being brought up to operating height from flat FL9000M The FL9000M suspension runs at two ride heights 228mm and 253mm refer to trailer builder for piping instructions Checking Dimension Ride Height 63 5mm Checking Dimension Air Suspension Service SECTION 9 Maintenance Schedule BEFORE ENTERING SERVICE IF THE OPERATOR IS IN ANY DOUBT ABOUT THE SAFETY OF THE VEHICLE HE SHOULD NOT OPERATE IT AND SEEK QUALIFIED ADVICE 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 section 8 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 AFTER FIRST 1000 KM Check all fastener torques according to the torque tables on Page 29 Examine all valves
Download Pdf Manuals
Related Search