4370

0201

-IM-E

NG

-R0

(20/

06/2

017)

This leaflet is purely for illustrative purposes and may not reflect correctly the supplied parts. The manufacturer reserves to amend the contents of it whenever neces-sary and without notice.

www.topdrivesystem.com

Rear integrative pneumatic suspension for

VOLKSWAGEN T5

Rear axle

EN

G TOP DRIVE SYSTEM Ref. :

4370020M

www.topdrivesystem.com

Pressure s cker (1X)

Black RILSAN pipe (10m)

INSTALLATION INSTRUCTIONS

PACKAGE CONTENTS

Unscrew lower shock absorber nut and bolt. This is necessary to provide more space to re-move the coil spring. Keep the screw. Is needed to lock again the shock absorber later.

LEFT SIDE

1 2 Uninstall original coil spring. To remove the spring, lower a bit the axle. Note: the picture is for the left side of vehicle. Same operations must be done for the right side of vehicle.

Right suspension (1x) Le suspension (1x)

Warning: Before starting any unistallation procedure, be sure to check there is no load on compo-nents, to avoid dangerous movements and to prevent damages and injuries. To avoid this be sure the rear axle is correctly supported.

LEFT SIDE

Pressure regula on KIT 12V DC Air compressor Control panel

Relè 12V with 20A fuse

Blue eyelet Faston (2x)

Blue female Faston (4x)

Red female Faston (2x)

Blue male Faston (1x)

Pneuma c system instruc ons (1x)

“T” pipe fi ngs

1: Maximum pressure regula on valve and pressure switch. 2: Infla ng panel with switch, infla ng/defla ng valve and manometer. 3: Relè with 20A fuse. 4: Compressor. 5: Ba ery. 6: “T” pipe fi ng. 7: Le suspension. 8: Right suspension.

Electrical and pneuma c wiring scheme

1

2

3

5

4

7

8

EXAMPLE CONNECTION LAYOUT

6

6

Wiring : 1. Disconnect ba ery ground wire. 2. Temporarily place compressor in its final installa on posi on. 3. Cut to size a nega ve(-) wire from ba ery at a ground point on vehicle. 4. Assembly the infla ng panel with switch, infla ng valve and manometer. 5. Mount the infla ng panel in a safe and easy accessible place inside the vehicle. 6. Install compressor (is recommended to use self locking components) and connect it to pneuma c system (see example layout in the next page). 7. Please refer to apposite instruc on for external aspira on filter installa on included with compressor. 8. Wire the posi ve(+) compressor cable at panel switch (see next page electrical wiring scheme). 9. Pay a en on to correctly protect the system with fuse. 10. Place the relè with fure as near as possible to the ba ery. 11. Verify all the wiring before connec ng posi ve(+) wire at the system. 12. Switch on compressor and let it running to set the correct pressure at pneuma c system. 13. Verify the system and eliminate all air leaks if present. Usage : Important : Never go above maximum working pressure. See technical informa on for correct u liza on. • Please respect usage specifica ons. Exceed maximum working pressure could result in compressor damage. • Compressore is equipped with automa c thermal protec on switch to prevent damages from overhea ng. • Do not try to start compressor if the protec on switch has stopped the compressor.

Put the infla ng panel switch in « OFF » posi on and let compessor cool off for 30 minutes. When compressor has cooled down, it is ready to start again.

• To avoid excessive ba ery usage and to obtain maximum performance, is recommended to use compressor while engine is running.

• Use compressor in well ven lated environments. Maintenance and repairs : • Periodically check electrical wiring and pneuma c connec ons. Clean and restore them if necessary. • Periodically check all the screws. Tighten if necessary. • Periodically check the air filter and replace it if necessay. Life span of air filter depends on working environment. • Periodically clean the cooling fins of compressor engine. • The compressor is equipped with a permanent lubricated engine and do not need any maintenance. • Never lubricate or grease the compressor. • All repairs must be executed by manufacturer or by an authorized workshop. • Important : Never touch compressor or its components with bare hands during or immediately a er usage. During and immediately a er usage, compressor will became very hot. Please wear protec on gloves if is necessary to touch compressor. Regola ons : • Maximum pressure must be regulated at 7,5 bar. • Warning beeper start if pressure drop under 7,5 bar. • Verify and regulate the pressure with the aid of infla ng panel manometer.

It is best to uninstall upper and lower coil spring caps. Note: the picture is for the left side of vehi-cle. Also the shock absorber is not in this position anymore.

3

Note: There is an hole on the rear part of axle. As showed in picture, the suspension pin must enter the hole. If necessary drill a bit the hole to ease the installation.

4

5

Connect the air spring to the pneumatic system an place it on the rear axle as showed in pictu-re. If necessary protect the air pipes with a sheat. Note: The upper air spring side is the one with the protective cover.

Place the air suspension in the same place of the removed coil spring. Please note that the suspensions are different for the left and right sides (pin and pipe fitting position).

6

LEFT SIDE LEFT SIDE

LEFT SIDE LEFT SIDE

Check the correct position of the air spring. The distance from the axle to chassis should be 220mm.

7 Distance is measured from upper suspension side to upper side of rear axle. Remount the shock absorber with the original nut and bolt. Note: Place the vehicle in driving position befo-re tightening the screws.

8

LEFT SIDE

Rear axle pneuma c suspensions installa on instruc ons This air suspension kit has been carefully developed especially for this vehicle. The air suspension should fit perfectly on a standard vehicle, not equipped with any op onal a ermarket parts. However, whenever a problem occours, plea-se contact your air suspension supplier. This manual has been carefully cra ed to give the best way to fit the air suspension. However, the manual is a random indica on of the technical specifica ons at any given me. ESI Italia reserves the right to make technical changes in the air suspension kit without any no fica on. Always place the vehicle on a car-li when working on it. Make sure the rear wheels are always supported. Make sure the vehicle is correctly secured when fi ng the air-suspension. When fi ng the wiring ESI Italia advises to disconnect the ba ery-terminal clamps. Please check your vehicle workshop manual if this conflicts with any electronic vehicle management equipment. Make sure that the new wiring does not conflict with the original vehicle wiring and electronics. When fi ng the air-suspension, make sure no parts are being damaged. The air-suspension is designed to support the manufacturer’s Gross Vehicle Weight Ra ng (GVWR). Never overload the vehicle, as it may result in damage to the air-suspension or vehicle. The vehicle should be weight when it is fully loaded and in a level condi on. This is to determine if the manufacturer’s recommended GVWR is exceeded. If the air-suspension fails, stop the vehicle and don’t drive with it. Only in an emergency the vehicle can be driven at low speed and with precau onary measures. Fi ng of the air suspension kit can only be done in a ESI Italia authorised workshop, equipped with all appropriate equipment and tools, by an authorised mechanic with proper training and experience in the following fields (all in the range of light commercial vehicles): - Mechanics - Electrics - Pneuma cs When fi ng the air-pipes and wiring make sure that they do not bend too much. Always cut the air-pipes in a right angle. Make sure that the air-pipes are clean inside. It is absolutely forbidden to secure air-tubes, cables or other parts to the brake lines of the vehicle. Secure all connectors properly and make sure that there is no stress on them. Whenever changes are made to the original corrosion protec on, restore it immediately. For this purpose use for example paint or spray wax. A en on: do not apply corrosion inhibitor to non metal parts! When the vehicle is in its ride-height, ghten all the bolts and nuts to the final torque. Whenever a torque men oned in this manual conflicts with the torque recommended by the vehicle manufacturer please use this one. Check the alignment of the rear-axle when the vehicle is in ride-height. Measure the distance between the inside of the rim and the chassis on both sides. A maximum difference of 3mm is allowed. In case of any conflicts on points men oned above, please contact your air suspension supplier for technical assistance.

Important safety instruc ons: • Do not dismount, modify, or repair by Yourself the compressor. For all services and repairs please refer to authorized

workshops. • Is recommended to not use compressor in wet environment. • Do not touch compressor if wet by water or other liquids. • Use compressor only at 12 Volt. • Do not leave compressor running una ended. • Use of compressor by minors is prohibited. Keep children away from compressor when it is running. • During and immediately a er usage, compressor will be very hot. Do not touch any part of the compressor with bare

hand, except ON/OFF switch. • Keep compressor away from flammable or explosive materials. • Do not use this product where oxigen is in use. • Use only with atmospheric air. • Do not use compressor while sleepy or drowsy. • This compressor is equipped with thermal security switch. When compressor cools off, it can automa cally restart. • Wear safety glasses during compressor u liza on . • Use compressor in well ven lated environment. Installa on : To avoid injuries or damages at vehicle and/or compressor, please carefully read the installa on instruc ons before start with compressor installa on. Every compressor and its components are carefully produced and packed. Before beginning the installa on please ve-rify the presence of all the components indicated in the instruc ons booklet. Compressor housing indica ons : The right choice of the place in which installing the compressor will contribute to guarantee its dura on. Please follow those direc ves : 1. Choose a flat and solid surface to place the compressor. 2. For best results, place compressor near the ba ery, so the wire cables are short and the dispersion is reduced. 3. In order to avoid overhea ng, place compressor in a fresh place. This will reduce the possibility of overhea ng. 4. The compressor is sealed, but not waterproof. Do not mount it where can come in contact with water. 5. The aspira on filter must be mounted where it can not draw water. This is also valid for the external aspira on filter. 6. If it is necessary to mount compressor far from ba ery, for example inside of vehicle, please use at least 1.3 mm² wire to prevent wire overhea ng. 7. Do not install compressor in a place where is stored flammable material.