Dunlop L.CRA.17D.C.M User manual

L.CRA.17D.C.M and
L.CRA.17D.4.C.M
DRW, DOUBLE REAR WHEEL DRIVE AND 4X4
VOLKSWAGEN CRAFTER (2017 ONWARDS)
MAN TGE (2017 ONWARDS)
INSTALLATION MANUAL
DUNLOPSYSTEMS.NL

2 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

1Foreword 4
2 Introduction 5
3 Very important notes 6
4 Overview 7
5 Instructions for installation 8
5.1 Recommended Tightening Torque 8
5.2 Preparation 8
5.3 Bump Stop Removal and fitting of Upper Bracket 9
5.4 Attachment of the LED-Lights Sensor 9
5.5 Attachment of the Lower Bracket and the Bellows 9
5.6 Fitting of Inflator Console 10
5.7 Tube Connection and Disconnection, Cutting and Routing 12
5.8 Bellow Inflation 13
5.9 Bellow Alignment 14
5.10 Maintenance 14
5.11 Check List 15
6 Installation pictures 16
7 Epilogue 19
Contents
3 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

1 Foreword
This manual provides instructions for the installation of an auxiliary air
suspension kit, developed specifically for the Volkswagen Crafter DRW /
4x4 double tires as also the MAN TGE DRW / 4x4 double tires (2017-
onwards).
To ensure correct installation of the kit, it is strongly recommend that
these instructions are read thoroughly before commencing any installati-
on work. Installation should only be carried out by a suitably qualified
mechanic or specialist installation facility. DSC Nederland will not accept
any responsibility for faults or defects arising from incorrect installation,
which automatically renders the guarantee invalid.
IMPORTANT: Manufacturer’s Declaration Form
A manufacturer’s declaration form is provided with your kit. Following installation
of the kit please ensure that this form is completed, signed by a qualified fitter and
a copy is returned to DSC Nederland by post, fax or e-mail. Our e-mail address is:
[e-mail]
4 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

2 Introduction
THANK YOU FOR CHOOSING AN AUXILIARY AIR SUSPENSION KIT FROM THE RANGE
OFFERED BY DSC NEDERLAND AUXILIARY AIR SUSPENSION IS FITTED IN TANDEM WITH
THE STANDARD STEEL SPRINGS OF THE VEHICLE SUSPENSION, AND PROVIDES ENHAN-
CEMENTS IN TERMS OF BOTH THE STABILITY OF THE VEHICLE AND THE COMFORT OF
THE PASSENGERS…
VEHICLE LEVELLING
Simply by varying the air pressure in the springs, the vehicle can be
levelled both front-to-rear and side-to-side. Keeping the vehicle level
optimises stability, ensures correct headlamp beam distribution and
reduces tyre wear arising from uneven distribution of weight.
STRAIGHT LINE STABILITY
Straight line stability is greatly increased at higher speeds, and when
subjected to buffeting from cross-winds or large overtaking vehicles.
REDUCED BODY ROLL
Body roll when cornering or negotiating roundabouts is significantly
reduced.
FATIGUE REDUCTION AND WEAR COMPENSATION
Suspension fatigue is reduced, so helping to prevent leaf springs from
sagging under repeated or constant loading. Any sagging already
present can be compensated-for. This is a particular benefit for motor-
homes, which are always fully laden.
RIDE COMFORT
Air springs help to absorb shock loads from uneven road surfaces,
therefore general ride quality is much improved.
5 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

3 Very important notes
IMPORTANT: Gross Vehicle Weight (GVW)
Air assist kits are not in themselves designed to increase the gross vehicle weight
(GVW) rating of a vehicle. They do not legally allow for carriage of a load greater than
the carrying capacity stated on the data plate of the vehicle.
Do not exceed the maximum load specified by the vehicle manufacturer.
• to avoid compromising passenger safety
• to prevent possible damage to the vehicle
• for legal reasons
VEHICLE UPRATING
Despite the above words of caution, it is possible to upgrade the weight
rating of your vehicle. This must be carried-out by a specialist supplier
that will:
• carry out any necessary modifications in addition to fitting the air
assist kit
• complete documentation as necessary to inform the Vehicle and
Operator Services Agency (VOSA) – a mandatory requirement
• supply and fit a new weight plate to replace the original plate
supplied with the vehicle
This process applies to United Kingdom registered vehicles. The process
in other countries may be different.
SAFETY GUIDANCE NOTE
The following very useful guidance note is available for free download
from the Health and Safety Executive (HSE)...
PM85, July 2007 Safe recovery (and repair) of buses and coaches fitted
with air suspension
The uniform resource locator (URL) for this document is…
http://www.hse.gov.uk/PUBNS/pm85.pdf
6 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

4 Overview
THE COMPLETE BELLOW AND BRACKET ASSEMBLY
IS SHOWN OF THE RIGHT SIDE BY THE DIAGRAM
BELOW.
NUMBER PART NUMBER DESCRIPTION QUANTITY
1 81.13.00.1.01.01* Top plate Left 1
2 81.13.00.1.02.01 Top plate Right 1
3 81.10.00.1.01.02 Clamb Strap outside 2
4 81.10.00.1.01.03 Clamb Strap inside 2
5 81.13.00.1.04* Lower bracket Left 1
6 81.13.00.1.05 Lower bracket Right 1
7** OP.LB.170-2.CPL** Air bellow 170/2 2
8 DIN 933-M8x20 Hexagon bolt M8 x 20 2
9 DIN 933-M8x16 Hexagon bolt M8 x 16 8
10 M8 Disc spring washer 10
11 DIN 933-M5x14 Hexagon bolt M5 x 14 1
12 DIN 125A-M5* Washer M5 1
13 DIN 9623-M5 Flange nut M5 1
4
13
8
7**
10
9
6
12
11
1
3
* Left side not in the assembly drawing
NOT IN THE ASSEMBLY DRAWING
• Tie wraps
• Black hose
• An inflate option
• Declaration of conformity
• Installation manual
7 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5 Instructions for installation
IMPORTANT: Preparation and Precaution
Before beginning installation, ensure that you have sufficient clearance between the
axle and the chassis. Use a jack if necessary. Install at one side of the vehicle at a time.
Pay attention to your safety at all times during installation - always use axle stands
to support the vehicle!
The position of the axle stands should be under the chassis NOT under the axle!
5.1 RECOMMENDED TIGHTENING TORQUE
During fitting of the air suspension system, it is recommended that nuts
and bolts are tightened in accordance with the following table...
THE FOLLOWING INSTRUCTIONS MAKE REFERENCE TO THE
DIAGRAMS ON PAGES 16 TO 18 INCLUSIVE.
5.2 PREPARATION
1. Secure the front wheels, use wheel chocks on both sides of both front
wheels.
2. Take the ground terminal from the battery when work to electricity
is involved.
3. Lift the rear of the vehicle till there is working space of approximately
15 cm between bump stop and rear axle.
METRIC TORQUE CHART IN N.m
SIZE CLASS 8.8 CLASS 10.9
M6 x 1 9.9 14.0
M8 x 1.25 24.0 34.0
M10 x 1.5 48.0 67.0
M12 x 1.5 61.0 89.0
M16 x 2 200.0 285.0
IMPORTANT:
• When both the bolt and nut are
made from steel use either class
8.8 or 10.9
• For all other materials, tightening
torque is left to the discretion of a
person skilled in the art
8 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5.3 BUMP STOP REMOVAL AND FITTING OF UPPER BRACKET
1. Remove the two bump stops (Figure 1 and 2).
2. Drill out the blind rivet (Figure 3) of the LED head light sensor. Use a drill of 5 mm (Not all models will have
this sensor).
3. The chassis bracket assembly has two parts (See Figures 4, 5 and 6). Put the two parts together and offer
them up to the frame left vacant of the bump stop. Now slide the upper of the two chassis brackets inside
the lower of the two until the assembly is loosely attached to the bump stop frame with the holes in
alignment.
4. Offer the upper bracket up to the chassis bracket assembly and attach it using a single M8 x 20mm bolt
and a single serrated washer (Figures 7 and 8).
5.4 ATTACHMENT OF THE LED-LIGHTS SENSOR
1. The sensor can be attached on almost the same position but now to the lib of the upper bracket (Figures 9
and 10) with the M5 x 14, washer and flange nut (Pos. 11, 12 and 13 page 6).
2. The sensor arm remains unchanged.
3. Our upper bracket is designed in the way that the sensor will be in the same position as it was. Still you
have to check the height of the headlights.
4. Correction can be done by shifting the clamp around the shock absorber a bit up or down, till the height
of the headlights is correct again.
5. Tighten the sensor arm bracket and check the height of the headlights again.5.5 Attachment of the Lower
bracket and the Bellows
5.5 ATTACHMENT OF THE LOWER BRACKET AND THE BELLOWS
1. Unscrew the two bolts from the bracket that attaches the torsion beam assembly to the axle (Figure11).
2. Reattach the bracket that secures the torsion beam to the axle, thereby also securing the lower bracket to
the axle (Figure 12).
Take care the lower bracket rests flat.
3. See Section 5.7 - “Tube Connection and Disconnection, Cutting and Routing” : Use black tubing for the
left-hand bellow and blue for the right-hand bellow.
4. Feed for the right side the blue (left side is the black hose) tube from the topside trough the biggest hole of
the upper bracket.
5. Manually compress the bellow and connect the tube to the air bellowthen bung the end of the tube to
maintain the compressed state (Figure 13).
6. Shift the air bellow carefully between the brackets and guide the tube (Figure 13).
7. Release the bung from the tube. This allows air into the bellow, which consequently expands upwards
towards the upper bracket
(Figure 14).
8. Attach the bellow to both brackets using two M8 x 16mm bolts and two serrated washers on both sides of
the bellow (Figure 14 and 15). Do not fully tighten at this stage because the bellow may require alignment
once inflated (see Section 5.9 and Figure 16).
9. The distance between the top face of upper plate of the bellow and the bottom face of the lower plate
should now be brought to approximately 14cm. Manoeuvre the bellow such that it is in good vertical
alignment between the upper and lower brackets and tighten the screws.
9 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5.6 FITTING OF INFLATOR CONSOLE
Your kit is supplied with one of these inflator options:
OPTION VALVES Two valves and a small bracket
OPTION MANO
(WITHOUT CONSOLE)
Two valves and two independent 10-bar
pressure gauges
OPTION 1 Two valves in a console with two
independent 10-bar pressure gauges
OPTION 2 Two valves in a console with two indepen-
dent 10-bar pressure gauges and a rocker
on/off switch to operate the electric motor
driven air compressor
OPTION 3 Four valves (two for raising the vehicle
(’UP’) and two for lowering the vehicle
(’DOWN’)) in a console with two indepen-
dent 10-bar pressure gauges. A pressure
switch operates the electric motor driven
air compressor to keep the air reservoir of
2.2-litre at pressure.
EXTRA A special dashboard panel is available for
OPTION 1 and OPTION 2 (2017—2019)
OPTION 3
10 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

Mount the console in a position of your choice whereby it is firmly fixed, has some protection
from the environment (particularly important for the console with gauges) and is easily
accessible. Suggested possible locations include.
‘STANDARD’ CONSOLE
• on the rear bumper
• at the rear beside the license plate
• on the chassis next to a rear wheel
• in a service shutter (motorhomes)
• beside the fuel cap
‘OPTION 1’, ‘OPTION 2’ OR ‘OPTION 3’
Console…
• in the vehicle cabin, within reach and sight of the driver
• Beside, under the driver seat
• in the wall of a cupboard (motorhomes)
• in a service shutter (motorhomes)
‘COMFORT’ PACKAGES
The ‘OPTION 2’ and ‘OPTION 3’ panels, as shown above, are each part of a Comfort
Package that is supplied with a compressor (and also an air reservoir in the case of the
‘OPTION 3’ panel) for ease of spring inflation and ride height setting. For further informati-
on please ask your dealer. The photograph below shows all of the parts of Comfort Package
‘OPTION 2’.
11 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5.7 TUBE CONNECTION AND DISCONNECTION, CUTTING AND ROUTING
CONNECTION AND DISCONNECTION
Tubes are connected as shown by the diagrams below:
A. Slide a nut over the end of the tube B. Push the tube onto the
connector as far as possible
C. Feed the nut up to the connector,
fully tighten by hand and finally
tighten one additional turn using
spanners
CUTTING
To achieve good sealing and air-tight fitting of tube ends to their connec-
ting parts, it is very important to cut tubing cleanly and squarely. A
dedicated guillotine action tubing cutter is recommended, or a craft knife
if such a tool is not available. Do not use electrician’s side cutters.
A dedicated tubing cutter
RECOMMENDED
Electrician’s Side Cutters
NOT RECOMMENDED
12 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

ROUTING
Study the underside of the vehicle and decide how to route each branch of the air circuit.
• To minimise the risk of chafing, avoid running tubing over metal edges as much as possible
• Avoid close proximity to heat sources such as the exhaust assembly
• Choose a route that provides as much protection as possible from dirt, debris and any
solid objects that may impact the underside of the vehicle
> It is recommended that tubes are guided alongside brake lines as much as possible.
Use cable ties (‘tie wraps’) to secure tubing to the chassis, taking care not to
over-tighten them.
5.8 BELLOW INFLATION
Once installation of the air assist kit is complete, inflate the air bellow to achieve the desired
ride height via the inflator console taking careful note of the following.
IMPORTANT: Maximum and Minimum Pressure
MAXIMUM PRESSURE 7.0BAR
MINIMUM PRESSURE 0.5BAR
Do not exceed 7.0bar (101psi), which is the recommended maximum charge pressure for
the air springs. The springs may be deflated if the vehicle is to be stored for a lengthy
period without use, but a pressure of at least 0.5bar (7.25psi) should be maintained at
all times in order to avoid possible compression damage to the springs.
With the vehicle standing at the desired ride height, it is recommended that the height of
the bellow itself should be between 13cm and 15 cm. For 4x4 vehicles with a 170/3 air bellow
should it be 16 cm to 19cm.
13 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5.9 SPRING ALIGNMENT
1. With the vehicle standing at the desired ride height, ensure that the
springs are correctly aligned as illustrated above and then tighten
the bolts to secure the bellow to both the upper and the lower
mounting brackets.
2. Always check if the air bellow won’t touch any obstacle
3. Be aware 4x4 uses 170/3, this are 3 steps air bellows
^ 3 steps air bellow
5.10 MAINTENANCE
Following installation, it is recommended that all metal parts are coated
with a protective substance such as body wax.
The system does not require very much maintenance other than…
1. To maintain air pressure in the springs. Much like a tyre, the system
may lose a little air over time.
2. To keep the air bellows clean. It is suggested that, when washing the
vehicle, the bellows are inspected and cleaned as necessary (pre-
ferable by spraying). Look in particular for stones or grit trapped
between convolutes, as this may damage the bellow.
3. Check before and after the winter period the wax coating. Re-wax
when necessarily
14 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

5.11 CHECK LIST
Before driving the vehicle following completion of installation of the auxiliary air suspension system,
please check:
All bolts tightened to the recommended torque (Page 7)?
Air springs set in alignment (Section 5.9)?
Enough free space around the air springs to avoid wearing?
All metal parts wax coated (Section 5.10)?
Manufacturer’s declaration form completed and a copy returned?
A wait of 24 hours is recommended in order to ensure
that the vehicle has maintained its stance and that there
are no air leaks present.
15 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

6 INSTALLATION PICTURES
^ L.CRA.17D.C.M - STANDARD ^ L.CRA.17D.4.C.M - 4X4
16 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

1
3
5
7
2
4
6
8
17 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

9
11
13
15
10
12
14
16
Spring out of alignment
mounting plate axes
offset
Spring in alignment
mounting plates parallel
and coaxial
CAUTION! - Before fully tightening the bolts that secure the air spring to the upper and lower brackets, set the
vehicle at ride height (spring height approximately 13, 14 cm) and ensure that the springs are correctly aligned.
18 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

7 EPILOGUE
DSC Nederland hopes that you enjoy the benefits that your DUNLOP air suspension system will provide for
you. To ensure optimal performance, we advise that you have your system checked frequently by qualified
personnel. As recommended in the fitting instructions, it is important to coat all the steel parts with a protec-
tive substance such as body wax
IMPORTANT: Manufacturer’s Declaration Form
A manufacturer’s declaration form is provided with your kit. Following installation
of the kit please ensure that this form is completed, signed by a qualified fitter and
a copy is returned to DSC Nederland by post, fax or e-mail. Our e-mail address is:
[e-mail]
As a condition of your warranty, modifications to the system may only be carried out by personnel of DSC
Nederland. Enquiries For general enquiries please contact one of our dealers. You can find them on our
website.
WWW.DUNLOPSYSTEMS.NL
19 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4 FEB 2021

DSC Nederland B.V.
Het Wegdam 22
7496 CA Hengevelde
Nederland
T+31 (0)547 333 065
F+31 (0)547 333 068
[e-mail]
Wwww.dunlopsystems.nl
DUNLOP and the Flying D device are trademarks
of Sumitomo Rubber Group and are used under
license by DSC Nederland B.V.