Stemco 830 User Manual
Aeris Installation, Service and Troubleshooting Manual
STEMCO Aeris
Installation Manual
Date: 5/29/2012
• 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.
• The rotary seal employed in AerisTM by STEMCO differs dramatically from currently available systems
and is targeted to increase the reliability and durability of these components substantially. The rotary
seal in an automatic tire inflation system is a critical component – it prevents the higher pressures
needed to inflate commercial tires (typically 100 psi) from leaking into the wheel end, which can
handle no more than 6 psi. Excess pressure can cause the wheel end seal to fail prematurely,
causing lubricants to exit the hub and leaving moving parts susceptible to wear and seizure – a
dangerous scenario. In addition to the high reliability and durability of the patented sealing system,
AerisTM by STEMCO also includes several one-way pressure relief valves per axle to ensure that the
wheel-end is never pressurized.
• AerisTM by STEMCO also includes a very sensitive electronic flow detection technology capable of
informing the driver whether the system is making a minor adjustment to tire pressure or if a major
leak is present. A “Smart Sense” wheel end identification option will inform the driver which wheel
end is taking air – saving time and labor in the search and repair of tire leaks.
• AerisTM by STEMCO represents a leap forward in automatic tire inflation technology. STEMCO starts
with an unwavering commitment to increase the safety of our roadways by protecting the wheel end
from damaging air pressure, and then added several additional safeguards and features. Aeris
augments our BatRF tire pressure monitoring systems to complete our suite of tire pressure
management solutions.
Rev: A
Page | 1
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.
Page | 2
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…………………………………………………………………………….7
System Overview……………………………………………………………………………….7
Aeris Overview…………………………………………………………………………..7
System Features………………………………………………………………………...7
Aeris Specifications……………………………………………………………………..8
System Operation……………………………………………………………………….8
How System Works……………………………………………………………8
System Components……………………………………………………………………9
Recommended Tool List………………………………………………………………..9
Aeris Installation................................................................................................................9
Trailer Preparation………………………………………………………………………9
Axle Preparation…………………………………………………………………………10
Drain Oil………………………………………………………………………….10
Remove Welsh Plug……………………………………………………………11
Drill Fixture (How to Make) and Use…………………………………………12
Drill & Tap Holes in Axle………………………………………………………12
Clocking Wheels………………………………………………………………………..16
Axle Hose Installation………………………………………………………………….18
Split Loom Tubing Protection Installation……………………………………………18
Center Vent Line Installation………………………………………………………….19
Axle Plug Installation…………………………………………………………………..20
Aeris Hubcap Assembly Installation………………………………………………….21
Control Box Installation………………………………………………………………...24
Connecting Airlines to Control Box…………………………………………………...26
Air Lines to Compressed Air Tank……………………………………………29
Tire Hose Installation…………………………………………………………………...31
Light Kit and Wiring Installation……………………………………………………….32
Decal Location………………………………………………………………………….39
Page | 3
Aeris Installation, Service and Troubleshooting Manual
System Installation Check…………………………………………………………………40
Maintenance………………………………………………………………………………….41
Check Tire Pressure…………………………………………………………………41
Regulator Setting…………………………………………………………………….42
Page | 4
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. Information accented by these words indicates a point of emphasis of importance. The
following definitions comply with ANSI Z535.4 and indicate the use of signal words as they appear
within this manual.
! DANGER: Indicates immediate hazards which will result in severe personal injury or death.
! WARNING: Indicates hazards or unsafe practices which could results in sever personal injury
or death.
! CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE: Indicates hazards or unsafe practices which could result in damage to machine or
equipment.
IMPORTANT: An operating procedure, practice or condition that is essential to emphasize.
! Safety alert symbol used to indicate a condition exists that may result in personal injury or harm to
individuals. It must be applied to DANGER, WARNING and CAUTION statements which emphasize
severity.
IMPORTANT: Please pay special attention to the information supplied in the Explanation of Signal
Words section. These words are used to help prevent immediate hazards, unsafe practices, sever
personal injury or death and damage to machines or equipment.
Important Safety Notices
• Proper maintenance, service and repair are important to the operation and reliability of the trailer
suspension system and its components. The procedures recommended by STEMCO as described in
this manual are methods of performing maintenance, inspection, repair and service. All warnings and
cautions should be read carefully to help prevent personal injury and to help assure proper installation
methods are used.
• Improper maintenance, service and repair can result in personal injury, vehicle damage, property
damage, unsafe operating conditions or void the manufacturer’s warranty.
• Carefully read, understand and follow all safety related information in this manual.
Page | 5
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.
! WARNING: Always wear proper PPE when installing and performing maintenance repair,
servicing equipment or cleaning tractor or trailer components.
! WARNING: Solvent cleaners can be flammable, poisonous and can burns or serious injury.
To help avoid serious personal injury, carefully follow the manufacturer’s product instructions
and guidelines. Please follow the procedures below:
• Wear proper eye protection
• Wear proper protective clothing to protect your skin
• Always work in well ventilated area
• Do Not use gasoline, or solvents that contain gasoline. Gasoline can explode and cause
serious personal injury or death.
• Hot tank solutions or alkaline solutions must be used correctly. Follow the manufacturer’s
product instructions and guidelines.
! WARNING: Avoid creating dust from brakes when cleaning around any brake components.
Dust from brake pads and/or parts is a possible cancer and lung disease hazard.
General Service Information
Before starting any work or installation, read, understand and comply with the following:
• Read all instructions and procedures.
• Company’s service, maintenance, installation and troubleshooting procedures.
• Manufacturer’s vehicle safety instructions when working on the vehicle.
• Manufacturer’s vehicle instructions not detailed in this service manual.
• Follow all local safety regulations and best safety practices when installing.
General Service Installation Notes
• Work must be performed by trained personnel.
• Use all recommended tools required to help avoid personal injury and damage to components.
• Be aware of potential power release of tensioned springs on brake chamber or the brake return
springs. The release of tension can cause injury.
• After installation perform operational checks and test the trailer to make sure the brakes are
functioning properly before releasing back into service.
Page | 6
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.O Box 1989
Longview, Texas 75606-1989
Phones: (800) 527-8492 | (903) 758-9981
FAX: (800) 874-4297 | (903) 232-3508
System Overview
• The Aeris tire inflation system is designed to automatically inflate tires that are below the target
pressure setting. The system uses air from the trailer’s compressed air tank. The compressed air
tank pressure setting must be higher than the targeted tire pressure setting. Failure to have the
air tank pressure above the target tire pressure prevents proper operation of the inflation system.
System Features
• Tire pressure is continuously monitored and adjusted automatically to the target tire pressure.
• Adjustable air pressure regulator is used for setting desired tire pressure target.
• An indicator light will illuminate when air is flowing to the tires.
• Does not pressurize axle tube (prevent contamination of seals).
• Rotary seal air leakage will not enter the wheel end, preventing oil contamination on the hubcap.
• Each wheel end has dual venting paths to prevent wheel end pressurization.
• Checks tire pressure constantly.
• Integrated check valves in the hoses isolate tires from system if a tire is damaged or leaking.
• Tire pressure check ports are integrated into each hose, eliminating the need to remove the hose
to check the tire pressure.
• An air filter is provided on the inlet air line to prevent particulates from clogging the system.
Page | 7
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.
• Minimum power requirement to operate: 9 Volts
• Indicator light current range: 50 mA to 600 mA
• Tire inflation capacity (per tire): 10 psi in 2-3 minutes
• The indicator light provides the following system information:
• No light: System is good
• Power up: Light blinks three times
• No pressure: Long flash followed by 2 blinks repeating.
• Low volume flow: Constantly on
• High volume flow: Blinking constantly
System Operation
How System Works
• The Aeris tire inflation system is designed to continuously supply filtered, regulated compressed
air to each tire on the trailer. There is no operation required of the driver for the system to function
normally. The only requirement of the driver is to verify the indicator lamp is functioning and to
monitor the system periodically.
• The Aeris system is preset to maintain a specific tire pressure in each tire. The pressure in the
trailer’s air tank must be maintained above the targeted pressure to allow the controller to
continuously supply and maintain the preset tire pressure to all tires.
! IMPORTANT: For Aeris controller to operate properly the air tank pressure must be greater
than the tire pressure target. The controller cannot supply tire pressure above the air tank
pressure.
• When the system is operating properly, the air tank will supply pressurized air to the Aeris
controller. The controller will supply regulated compressed air to the air lines going to each tire. If
a tire is low, air from the trailer air tank will inflate the tire until the targeted tire pressure is
achieved. Regulated air flowing from the controller to the air lines and tires may cause the
indicator light to remain on until the target pressure is reached. Constant pressure remains and is
maintained in air lines and tires at the targeted pressure.
Page | 8
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. Operator should seek service at the next available opportunity.
• Remaining tires are protected from pressure loss by check valves integrated into each tire hose.
System Components List
• Hubcaps
• Spindle plug driver and plugs
• Air lines and fittings
• Light indicator and electrical wiring
• Control box with regulator and filter
• Control box mounting bracket
• Flexible wiring conduit
• Hardware kit
Recommended Tool List
• 3/8” Drill
• Drill Bushings (Type SF) K, 7/16” and 9/16”
• Drill Bits K, 7/16” and 9/16”
• Medium to Heavy Duty Extension Cord
• Wire Strippers
• Wire Crimper
• Combination Wrenches – 1/2", 9/16” and 11/16”
• Hammer
• Drill Fixture (See page 12)
• Ratchet and Sockets - 1/2", 9/16” and 11/16”
• #2 Phillips Screwdriver Bit for Drill
• Cutting and Tapping Fluid
• 10” Adjustable Wrench (Crescent)
Page | 9
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.
See Figure 1
! WARNING: To prevent serious eye injury, always wear approved safety glasses when
performing trailer maintenance and service.
Aeris Installation, Service and Troubleshooting Manual
• Park trailer on level surface.
• Set trailer parking brake.
• Chock each trailer wheel.
• Place jack stands under trailer.
• Bleed braking system of compressed air.
Axle Preparation
Drain Oil
• Place drain pan under hubcap for oil.
• Remove bolts from all hubcaps and allow oil to drain from each wheel end.
Figure 1
Page | 10
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.
• If you do not have a slide hammer you may be able to remove the welsh plug by using a chisel
and hitting the welsh plug off center. This should cause the plug to start turning inside the spindle
unless there is a shoulder behind the welsh plug. Once the plug has turned enough to grab it with
a pair of pliers and pull until plug comes out.
• If plug cannot be removed, drill a 1/2” hole in the welsh plug. Make sure as you are drilling the
hole you don’t score the inside diameter of the spindle bore.
• Insert a long steel rod into the 1/2" hole until it hits the back side of the welsh plug in the opposite
spindle. Steel rod must be longer than the length of the axle. Use a hammer to hit the rod and
knock the welsh plug out. Pull rod out and repeat procedure on the plug with hole with the 1/2"
hole in it. Repeat procedure for second axle. See Figure 2
Aeris Installation, Service and Troubleshooting Manual
Drain Pan Drain oil into pan from each wheel
Drill hole off center for slide hammer or rod. Rod running through axle to other welsh plug
Figure 2
Page | 11
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. Drill bushings - Type SF (3 Sizes) - K,
7/16” and 9/16”.
Figure 3 Figure 4
Determine Axle Requirements:
• Axle with nothing installed – Start at “Drill and Tap Hole”.
• Axles with pre-drilled holes but no hardware installed – Start at “Axle Hose Installation”
• Axle with “Other” tire inflation system – remove airlines and fittings– Start at “Axle Hose
Installation”
Drill and Tap Holes
• Clean off axle for drilling holes for air fittings.
• Review the sketch of how drill fixture is made. See Figure 3 & 4
• Drill holes using the drill fixture (Figure 4) to help facilitate in the drilling and tapping of the three air
fittings. Use small level and c-clamp to hold fixture in place. Use drill lubricant for holes.
Page | 12
Aeris Installation, Service and Troubleshooting Manual
Note:
! 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.
! WARNING: When drilling the 7/16” hole, be careful as the drill bit breaks through the inside
of the axle! The drill bit can hang up causing the drill to twist in your hands. When
breaking through the inside of the axle, apply less pressure and drill at a slower speed.
• Use either an angle drill or standard drill where room permits. Use lubricant for drilling and
tapping holes. With drill fixture is in place (Figure 5) insert the “K” drill bushing in fixture and drill a
pilot hole using a “K’ drill bit. Next insert the 7/16” bushing and drill the hole using a 7/16” drill bit.
Next insert the 9/16” bushing in fixture and using a 1/4-18 NPT tap the hole. Repeat procedure on
all 3 holes in each trailer axle. When tapping holes leave approximately 6-7 threads sticking out of
the axle. STEMCO recommends using an L1 plug gage to measure proper depth. Do not run tap
all the way into the axle.
! WARNING: When finished drilling holes, use a cleaning wand connected to high pressure
air to blow out shavings from inside of the axle. Use safety glasses.
1. Axle
2. Torpedo Level
3. C-Clamp
4. Drilling Fixture
Before drilling any holes in axle make sure they will
not interfere with any suspension components or
brake components. Contact STEMCO for technical
assistance at 903-758-9981 in U.S.A.
Figure 5
Page | 13
Loading...