Aeris Installation, Service and Troubleshooting Manual STEMCO Aeris Installation Manual Date: 5/29/2012 Rev: A • AerisTM by STEMCO, an advanced automatic tire inflation system based on patented rotary sealing technology and precision electronic airflow detection. The system is designed to keep commercial trailer tires properly inflated using air pressure from the trailer’s braking system.
Aeris Installation, Service and Troubleshooting Manual General View of Aeris Components Installed. Refer to this installation guide on how to install the Aeris system on trailers.
Aeris Installation, Service and Troubleshooting Manual Table of Contents General Information…………………………………………………………………………….5 About this Manual………………………………………………………………………..5 Explanation of Signal Words……………………………………………………………5 Important Safety Notices………………………………………………………………..5 General Service Information……………………………………………………………6 General Service Installation Note……………………………………………………...6 Contact STEMCO………………………………………………………………………….7 Literature Link…………………………………………………………………...7 Phone…………………………………………………………………………….
Aeris Installation, Service and Troubleshooting Manual System Installation Check…………………………………………………………………40 Maintenance………………………………………………………………………………….41 Check Tire Pressure…………………………………………………………………41 Regulator Setting…………………………………………………………………….
Aeris Installation, Service and Troubleshooting Manual General Information About This Manual This manual is provided to support the STEMCO Aeris tire inflation system. The manual provides the following information needed to install service and troubleshoot the Aeris system. Explanation of Signal Words Please pay attention to special symbols used through this manual to convey important information. Hazard signal words such as DANGER, WARNING, CAUTION, or NOTICE are used throughout this manual.
Aeris Installation, Service and Troubleshooting Manual ! WARNING: DO NOT modify or rework parts. Use only STEMCO Aeris authorized replacement parts. Use of substitute, modified or replacement parts not authorized by STEMCO may not meet STEMCO’s specifications. This may cause the part to fail which could result in loss of vehicle control and possible personal injury or property damage. Do not modify parts without STEMCO’s authorized written permission.
Aeris Installation, Service and Troubleshooting Manual Contact STEMCO STEMCO reserves the right to make changes and improvements to our products and literature at anytime. Please view STEMCO website for the latest version of this manual. www.STEMCO.com/library/installation-instructions. STEMCO LP 300 Industrial Blvd. Longview, Texas 75602 P.
Aeris Installation, Service and Troubleshooting Manual Aeris Specifications • Tire pressure setting range: 70-120 psi • Pressure check interval: Continuously supplies air to tires • System power requirements at 12VDC: < 12W.
Aeris Installation, Service and Troubleshooting Manual • If a tire is leaking or there is a leak in the lines, the indicator light may illuminate and stay on. If the indicator light stays on for more than 10 minutes, the system is attempting to inflate the tire or trying to correct for the air line loss to the targeted air pressure. If this happens, the operator should stop and check the tires manually to determine if it’s safe to continue to operate the vehicle.
Aeris Installation, Service and Troubleshooting Manual Aeris Installation Trailer Preparation ! WARNING: Before starting any work on trailer, park trailer on a level surface. Chock all wheels in front and back of each wheel to prevent the trailer from moving. Support the trailer with safety jack stands. Do Not work under vehicle supported by jack stands only! Jacks can slip and fall over. Serious personal injury or damage to components can result.
Aeris Installation, Service and Troubleshooting Manual Drain Pan Drain oil into pan from each wheel Welsh Plug Removal • Remove welsh plugs. Drill a small hole off center in welsh plug. Hole should be smaller than plug removal spear on the end of slide hammer. Using a slide hammer fitted with a welsh plug removal spear to remove the welsh plug. Be careful not to score the inside diameter of the spindle bore.
Aeris Installation, Service and Troubleshooting Manual • Cover bearings and axle nut with clean towel to prevent contamination. • Inspect the spindle bore for burrs. Remove any burrs using straight die grinder with light grade flapper sanding wheel. Clean the bore of any grinding debris. • Check inside spindle to verify that the axle is hollow, which is required for air line passage. Drill Fixture (Suggested) Drill fixture for aligning holes on axle. 1. Drill fixture 2. Drill bushing lock screw 3.
Aeris Installation, Service and Troubleshooting Manual 1. 2. 3. 4. ! WARNING: The use of a drill fixture is recommended. Drilling free hand can create oblong holes. Drilling should be done at a medium speed. Keep drill straight when boring holes. Tapping should be done by hand only. Do not use a drill for tapping. The use of a drill to tap holes can lead to threads being too deep or breaking the tap.
Aeris Installation, Service and Troubleshooting Manual Axle Manufacturer Hendrickson Hendrickson SAF Holland AXN AXN Meritor Type INTRAAX / VANTRAAX TRLAXLE TAPER Tiremaxx TIS Trax-Pro 50 Location A See Figure 6 See Figure 7 See Figure 8 See Figure 7 See Figure 9 See Figure 7 Location B See Figure 6 See Figure 7 See Figure 8 See Figure 7 See Figure 9 See Figure 7 Figure 6 Figure 7 Page | 14
Aeris Installation, Service and Troubleshooting Manual Figure 8 Figure 9 Page | 15
Aeris Installation, Service and Troubleshooting Manual Component Installation Instructions • Wheels on each wheel end (dual tires) must have the valve stems clocked approximately 180° apart for installation of airlines to Aeris hubcap and valve stems on tires. Clocking should be done prior to installing Aeris system. See Figure 10 Clocking Wheels • Clocking dual wheels is important. Proper clocking allows the inner and outer valve stems to align with the hose attachment fittings on the Aeris hubcap.
Aeris Installation, Service and Troubleshooting Manual Figure 11 Dual wheels with 2 hand holes, or aluminum wheels with small round valve stem clearance holes require a second alignment procedure to ensure the hoses will not touch the wheel. To ensure perfect alignment between the hose attachment fittings on the hubcap and valve stems, the wheels may need to be rotated one stud clockwise or counterclockwise. See Figure 11.
Aeris Installation, Service and Troubleshooting Manual Axle Hose Installation ! WARNING: Before pushing the air line tubing into the axle, disassemble the pass through fitting and place the components over the end of the air line in this order: See Figure 12 • • • Pass Through Cap Rubber O-Ring Pass Through Fitting Body Now place a piece of masking tape over the end of the air line or plug the end of it so no debris can get inside the line as it is being pushed through the axle towards the wheel end.
Aeris Installation, Service and Troubleshooting Manual Split Loom Tubing Protection Installation • Place one of the supplied split loom tubing protection sleeves over the air line tubing of each spindle end to help protect against sharp edges inside the axle. Repeat steps 1-4 on remaining axle wheel ends. • The air line from the spindle end going to the fitting on the axle fitting can now be cut. Make sure to cut the tubing long enough to reach just past the center of the axle.
Aeris Installation, Service and Troubleshooting Manual Axle Plug Installation • Install the axle plug using the axle plug installation tool. The tubing passes through the center of the axle plug which is then inserted into the hole on the installation tool. Align the axle plug with the axle spindle and push leading edge of axle plug into spindle bore.
Aeris Installation, Service and Troubleshooting Manual Aeris Hubcap Assembly Installation • ! Place the hubcap gasket over the tubing before inserting it into push lock fitting on hubcap. If you are installing a grease application hubcap, make sure to follow recommended manufacturing guidelines for putting grease in bearings before you install the hubcap. IMPORTANT: Make sure grease is applied before installing grease hubcap if hubcap is a grease application.
Aeris Installation, Service and Troubleshooting Manual • Pull on the air line coming out of the axle until you feel it get tight (gently). Now push the pass through fitting body down the air line and tighten it into the axle. • Next push the rubber o-ring and the pass-through cap down on the tubing to the fitting. • Before you tighten the pass through cap, push 4-5” of air line back into the axle, making sure not to kink the air line.
Aeris Installation, Service and Troubleshooting Manual Figure 17 • ! Depending on your hubcap type, Remove plug on hubcap and fill with oil to appropriate levels for safe operation. Allow oil levels to stabilize and add oil until at correct levels for each hubcap. IMPORTANT: Make sure oil levels in each hubcap are at the recommended levels for safe operation before using the trailer. Fill and allow oil to settle then check oil levels again. Add as needed to reach the recommended levels.
Aeris Installation, Service and Troubleshooting Manual Control Box Installation • Install control box mounting bracket with hardware provided. Mounting bracket can be mounted flush against the back of bracket, flush against top of bracket to a cross member using top mounting holes or welded to the frame. If welding, weld the bracket to the frame before attaching the control box to the bracket.
Aeris Installation, Service and Troubleshooting Manual • The control box has several mounting options. In all mounting options the 5/16” sealing washer, lock nuts and flat washers must be used. The sealing washer is always on the inside of the box. 1. Attach the box (without the bracket) directly to a cross member or frame section using the three 5/16” mounting holes in the bottom of the box. Be sure to leave room at the top for the door to open up. 2.
Aeris Installation, Service and Troubleshooting Manual Connecting air lines to control box • After the hubcap is tightened down, push the rubber grommet on the air line down against the body of the fitting and tighten the nut. Take the tubing from each spindle end and insert them into the air line tee fitting over the center of the axle. It may be necessary to trim off excess tubing going to the center of the axle. Repeat this step on all axles.
Aeris Installation, Service and Troubleshooting Manual Figure 20 Page | 27
Aeris Installation, Service and Troubleshooting Manual Figure 21 Page | 28
Aeris Installation, Service and Troubleshooting Manual Figure 22 Air Lines to Compressed Air Tank ! IMPORTANT: Open petcock valve on compressed air tank to release air pressure from tank. Once compressed air is drained from the tank, close the petcock valve. • Remove large 3/8” Plug from side of compressed air tank. • Install the 3/8” NPT-M x 1/4” NPT-F bushing. • Install the 1/4” nipple. • Install “Inlet” side of the Pressure Protection Valve on nipple.
Aeris Installation, Service and Troubleshooting Manual Figure 23 Item 1. 2. 3. 4. 5. 6. 7. 8. 9.
Aeris Installation, Service and Troubleshooting Manual Tire Hose Installation • Attach air hoses to the hubcap and the inner and outer valve stems. The hose with the 180° fitting attaches to the outer valve stem. Turn the valve stem swivel nut on the fitting until the rubber gasket just makes contact with the valve stem, then turn the nut 1/2 turn more to ensure proper sealing. Now push the hubcap end of the tubing into the brass hose adapter fitting and turn the nut until the fitting is snug.
Aeris Installation, Service and Troubleshooting Manual Figure 26 Light Kit and Wiring Installation • Once the control box is mounted and the air lines are connected to the controller, the electrical wiring and light kit can be installed. Improper wiring or operation of Aeris system can lead to the driver not being aware the tire inflation system is not working correctly.
Aeris Installation, Service and Troubleshooting Manual Figure 27 Item Qty Description 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Used to connect light to light and 7 pin power box. Used to attach light and P-clamps to trailer Used to clamp down wire from light to trailer and to 7 pin power box Connectors for end of wires to 7 pin power box. Used to connect white, yellow, and brown wire to Aeris controller box.
Aeris Installation, Service and Troubleshooting Manual ! IMPORTANT: Make sure to run the 3 wire cable along the same path the airline from the brakes is routed. This will insure that you have enough slack in the electrical line to keep it from be damaged by any moving parts on trailer. See Figure 29 Figure 28 ! Figure 29 IMPORTANT: Do not allow 3 wire cable to rub against a sharp edge of a hole or straight edge of a structural cross member as cable is being routed through the trailer.
Aeris Installation, Service and Troubleshooting Manual • Once wire cable is pulled to the mounted controller box at the back of the trailer cut the cable. Make sure to leave enough wire to have about 12” of wire inside the control box. • Pull wire cable into the bottom of the control box through the cable glade. Once wire is inside the box, tighten the nut to seal up around the cable.
Aeris Installation, Service and Troubleshooting Manual ! • Take the light and using the pigtail provided plug the pigtail into the 2 holes on the back of the light. Plug the square flat ends into the light. Make sure connectors snap in place fully. • Now on the other end of the pigtail, remove the 2 plugs in the ends of the connectors and plug in the wire extension. Make sure connectors snap in place fully. • Mount light in front corner of or side of trailer.
Aeris Installation, Service and Troubleshooting Manual Figure 32 ! • Next tuck all the wires inside the 7 pin terminal box and install the cover back on the box. Make sure you don’t trap any wires between the cover and the box that could cause the wire to short. • Use tie wraps to attach 3 wire cable and wire cable from the light indicator to the airlines leading out of the 7 pin connector box.
Aeris Installation, Service and Troubleshooting Manual Figure 33 Page | 38
Aeris Installation, Service and Troubleshooting Manual Decal Location • Place decals on front of trailer by the indicator light and on the inside and outside of the control box cover. See Figure 34 .
Aeris Installation, Service and Troubleshooting Manual System Installation Check • After the Aeris system is completely installed, but before the trailer is put back into service, all air system connections need to be checked for leaks. Apply a soapy/water solution to all air connections. If bubbles appear at any fitting or air connection, check connection to verify it is tight. Follow Instructions Below: Make sure the petcock valve on the trailer air tank is closed.
Aeris Installation, Service and Troubleshooting Manual Maintenance Check Tire Pressure • Although the Aeris tire inflation system is designed to detect and fill a tire that’s leaking during vehicle operation, STEMCO recommends you inspect the tires for normal wear and damage at regular intervals and check the tire pressure as follows. • Remove the metal cap from the check port that is provided on each hose. See Figure 35 Figure 35 • Check pressure going to each tire using a pressure gauge.
Aeris Installation, Service and Troubleshooting Manual Regulator Setting • It’s recommended that you check the regulator pressure 4 times a year to verify the regulator is still set at the desired pressure setting. • Open the cover to the control box. • Remove the metal cap on the check port fitting on the regulator. • Check the pressure with an accurate gauge, such as a master gauge. • If the pressure is correct, replace metal cap and close the lid.
Aeris Installation, Service and Troubleshooting Manual CERTIFICATIONS (USA) This unit complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. FCC ID: SRA-830 This equipment equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules.