Dunlop L.SPR.18D.C.M User manual

L.SPR.18D.C.M and
L.SPR.18D.4.C.M
DRW, DOUBLE TIRES, WDB 907 AND 4X4
MERCEDES BENZ SPRINTER 500 (2018-ONWARDS)
INSTALLATION MANUAL
DSCSYSTEMS.NL

2 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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 and Lower Bracket 9
5.4 Attachment of the Bellows 9
5.5 Attachment of the LED-lights Sensor 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 Spring Alignment 14
5.10 Maintenance 14
5.11 Check List 15
5 Instructions for installation 16
6.1 Special Model and 4x4 19
7 Epilogue 20
Contents
3 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 2021

1 Foreword
This manual provides instructions for the installation of an auxiliary air
suspension kit, developed specifically for the Mercedes Benz Sprinter
500, double tires, WDB 907 and 4x4 (2018-onwards).
To ensure correct installation of the kit, it is strongly recommended that
these instructions are read thoroughly before commencing any
installation 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 | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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
ENHANCEMENTS IN TERMS OF BOTH THE STABILITY OF THE VEHICLE AND THE
COMFORT OF THE PASSENGER.
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
motorhomes, 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.
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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 | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 2021

4 Overview
THE COMPLETE BELLOW AND BRACKET ASSEMBLY
ARE SHOWN OF THE LEFT SIDE BY THE DIAGRAM
BELOW.
NUMBER PART NUMBER DESCRIPTION QUANTITY
1 49.11.00.1.01.01 Top plate Left 1
2 49.11.00.1.02.01* Top plate Right 1
3 49.11.00.1.01.02 Clamb Strap outside 2
4 49.11.00.1.01.03 Clamb Strap inside 2
5 49.11.00.1.04 Lower bracket Left 1
6* 49.11.00.1.05 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-M6x20 Hexagon bolt M6 x 20 2
12 DIN 125A-M6 Washer M6 2
13 DIN 9623-M6 Flange nut M6 2
11/12
13
5
9
10
7**
8
4
3
* Right side not in the assembly drawing
** For 4x4: OP.LB.170-3.CPL (air bellow 170/3, 2 pcs)
NOT IN THE ASSEMBLY DRAWING
• Tie wraps
• Blue hose
• An inflate option
• Declaration of conformity
• Installation manual
1
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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 19 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.
TIGHTENING TORQUE IN Nm
SIZE CLASS 8.8 CLASS 10.9
M6 x 1.0 11.3 16.5
M8 x 1.25 27.3 40.1
M10 x 1.5 54 79
M12 x 1.75 93 137
M16 x 2.0 230 338
IMPORTANT:
• When both the bolt and nut are
made from steel use either class
8.8 or 10.9
• For all other dimensions and
tighening torques is left to the skills
of a well-trained person
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5.3 BUMP STOP REMOVAL AND FITTING OF UPPER AND LOWER BRACKET
1. Remove the two bump stops (Figure 1).
2. Remove the holder of the cable loom and the 2 nuts of the sensor
(Figure 1). Not all models will have this sensor.
3. Remove the M10 Bolt of the Sensor arm of the connection to the rear axle (Figure 1).
4. Remove the small flange that protrudes from the top of the axle at both ends, (Figures 3 and 4) leaving a
smooth flat surface
5. Remove the two bolts from the bracket that attaches the torsion beam assembly to the axle (Figures 1 and
2).
6. Reattach the bracket that secures the torsion beam to the axle, thereby also securing the lower bracket to
the axle (Figures 5 and 6). Take care the lower bracket rests flat.
7. The chassis bracket assembly has two parts (See Figures 7 and 8). 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.
8. 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 9 and 10).
9. The cable loom can be attached with a ty-wrap trough a slot of the sensor connecting point at the top of
the upper bracket.
10. The sensor can be attached on the original position.
5.4 ATTACHMENT OF THE BELLOWS
1. 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.
2. Feed for the left side the black tube from the topside trough the biggest hole of the upper bracket.
3. Manually compress the bellow and connect the tube to the air bellow then bung the end of the tube to
maintain the compressed state (Figure 11).
4. Shift the air bellow carefully between the brackets and guide the tube (Figure 11).
5. Release the bung from the tube. This allows air into the bellow, which consequently expands upwards
towards the upper bracket (Figure 12).
6. Attach the bellow to both brackets using two M8 x 16mm bolts and two serrated washers on both sides of
the bellow Figure 12. Do not fully tighten at this stage because the bellow may require alignment once
inflated (see Section 5.9, Figure 15).
7. 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.
5.5 ATTACHMENT OF THE LED-LIGHTS SENSOR
1. The sensor can be attached on almost the same position but now to the upper bracket (Figures 13 and 14)
with the M6 x 20, washer and flange nut (Pos. 11, 12 and 13 page 8).
2. The sensor arm can be attached to the protrusion of the lower bracket with it’s original screw (Figures 13
and 14).
3. Check the height of the headlights, this can be corrected by releasing the M6 nuts and to manoeuvre the
bracket till the height of the headlights is correct again.
4. Tighten the sensor bracket and check the height of the headlights again.
9 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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
independent 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
independent 10-bar pressure gauges. A
pressure switch operates the electric motor
driven air compressor to keep the air
reservoir of 1.9 litre or 0.5 gallon at pressure
EXTRA A special dashboard panel is available for
OPTION 1, OPTION 2 and OPTION 3
OPTION 3
10 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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
information please ask your dealer. The photograph below shows all of the parts of Comfort
Package ‘OPTION 2’ and ‘OPTION 3’.
OPTION.2 OPTION.3
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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
connecting 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 | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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.
ONCE THE INSTALLATION OF THE AIR ASSIST KIT IS COMPLETE:
• Inflate the air bellows to achieve the desired ride height via the inflator console.
• To achieve a correct ride height, the rear of the vehicle is approximately 6 cm higher than
the front of the vehicle. That will correspondent with a bellow height between 13 cm and
15 cm.
• The correct used pressure is up to the discretion of the installer, but is mostly between the
1.5 bar and the 4.5 bar.
• The pressure for driving your vehicle is depending on the weight of the vehicle and the
condition of the original springs.
• Always keep in mind that you are using air assist suspension, that means helper springs,
they are designed to help. Do not let them take over the original springs.
• Because our system is independent between the left and the right side, it is not a problem
to inflate one side more to achieve the same height on the left and also on the right side.
• Once you know the pressure on your left and on your right side, make good notice of it, so
you can check the pressure of your system every time you start driving.
• The note here below is for extreme situations.
IMPORTANT: Maximum and Minimum Pressure
MAXIMUM PRESSURE 7.0 BAR
MINIMUM PRESSURE 0.5 BAR
Do not exceed 7.0 bar (100 psi), 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 0.5 bar (7 psi) should be maintained at all
times in order to avoid possible compression damage to the springs.
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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
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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 8)?
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.
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6 INSTALLATION PICTURES
16 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 2021

1
3
5
7
2
4
6
8
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9
11
13
15
10
12
14
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 | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 2021

6.1 SPECIAL MODEL AND 4X4
Not very often an extra ’Spacer’ is installed under the leaf spring. This means you have to
rotate it 180 degrees and detach the extra connected protrusion. Don’t cut it. To do this you
need to:
1. Unscrew the U-Bolts
2. Lift the chassis approximately 2.. 3 cm
3. Take care the rear axle is not lifted, in this way there is space to remove the ’Spacer’
4. Remove the protrusion by loosening the two Allen key bolts
5. Rotate the ‘spacer’ 180 degrees, to create space for the air suspension kit.
6. Tighten the U-bolts according the recommended torque (Garage manual of Mercedes).
7. Now you can start at page 7 of this manual
8. Be aware 4x4 uses 170/3, these are 3 steps air bellows
19 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 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
protective 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.DSCSYSTEMS.NL
20 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | MERCEDES BENZ SPRINTER 500 L.SPR.18D.C.M (AND 4X4) (2018-ONWARDS) JULY 2021