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INSTALLATIONINSTRUCTIONSLevelling Valve
Quality
Performance
Safety
Innovation
Application
The levelling valve is installed as a level control valve forload depended control of the volume of the air bellowsat vehicles with air suspension. Thereby are, accordingto the version, addition functions, such as 2. drive height,through a lap position control possible.
Operation
Levelling valves are fixed to the vehicle chassis andjoined with the control lever over a linkage with theaxle. The valve is switched in state of rest in the so-called lap position, i.e. both inlet as well as outlet areclosed. By loading the vehicle the chassis (frame) approa-ches to the axle, this way the linkage and the controllever is lifted and over the driving axle, excenter andpiston the inlet is opened. Supply air of connection 1flows now via the check valve , over the opened inlet,through the room between piston and inlet parts viaconnection 21 and 22 to the air bellows. Thereby thechassis (frame) is raised so far above, until the controllever is horizontally again, therefore in the lap position.By unloading the vehicle the chassis is raised becauseof the higher bellow pressure. By means of the linkagethe control lever is moving downward. The movementof the control lever transfers over the driving axle as wellas the excenter to the piston, which opens at hisdownward trend the outlet. Through the open outlet airflows now from the air bellows in to atmosphere, wherebythe chassis (frame) again is lowered to the drive position,(levelling valve control lever horizontally). At vehicles withonly one levelling valve per axle(bogie), the air bellowsof the left and right side will be provided from this onelevelling valve with air. For the avoidance of instabilitiesat cornering valves are anticipated for such usings witha cross restriction. Through a particular design the inletvalve part will provide herewith a delayed pressurizationbetween connection 21 and 22 and so between left andright side of the vehicle (caution by exchange).At the versions with a lap position control a 2nd driveheight can be realized. With it a so-called kneeling (one-sided lowering of the chassis) is possible e.g. at bussesand/or you get it at vehicles with lift axles. Herewiththe levelling valve is controlled over an external controlport and shifts the lap position. Thereby it is possible toraise or lower the chassis around a certain value. Atlifted axles the lifted wheel gets no touch of the groundwhen passing through a ground wave and is subject tothus no increased tire wear. A further use is the adjust-ment at different saddle heights.
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1Cutting section 612 0.. ...
Air flow diagram 612 0. ...
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1
2
1, 2
20
19, 21
Version A
Version B
Version A
3
4
5
3 - 5, 10 - 17Assembly instructions
Mechanical part
The levelling valve has to be installed vertically with belowdirected exhaust. For fixing use at least two screws M8.With application by only one valve per bogie the valvemust be fastened in the area of the middle of the axle.The freedom of movement of the excenter axle is to bechecked. The linkages are to be installed distortion free.
Pneumatic part
At the valves with push-in fittings use as pneumaticconnections plastic pipes 8x1 in accordance with DIN74 324 or ¼” x 0,04 in accordance with SAE J844. Whenassembling the pneumatic pipes, care should be takento ensure that the pipes are cut square, to the requiredlength and are free from burrs. Before inserting the pipesin the push-in fittings support sleeves, e.g. in accordancewith HALDEX order number 032 0490 09 should beinstalled in the ends of the pipes. Pipes are to be insertedat least 22 mm deep in the connections.*In the event of paint/coating work all open connectionsand the exhaust port are to be protected by suitablemeans to avoid penetration of the paint/coating. Afterpainting/coating remove this protect material.In the supply coming from the air reservoir a line filter isto be installed (guard against pollutions).
Setting
After installation of the valve and connecting the pipefittings the length of the connecting - rod must bedetermined between axle and valve, after the vehiclechassis was lifted on the desired height (vehicle manufac-turer - statements). The raising of the frame or chassisto these desired height is reached by lifting the controllever in position „charging“. At this process the air bellowsare inflated with air.At reaching the desired height the control lever must bepositioned immediately in the lap position, which can bethe horizontal position (depend to version), and fix it witha locking pin (d=4h8) on housing and on bore of thespindle. The necessary length of the connecting rodbetween the linkage to axle and the linkage at the controllever can be determined now, and the connectingrod can be fastened. The connecting rod is to beconnected to this in the rubber linkages and fastenedwith the anticipated hose clamps.Subsequently locking pin is to be removed again.
*) After removal of the retaining ring it is possible toremove the plastic pipe by pushing the clampring in. (e.g.at exchange).
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Ex factory the lap position is setted in the horizontalposition of the control lever (not on versions612 036 001 / 051 001 / 011. If no flawless lapposition can be reached in the horizontal position then acorresponding correction is possible:For the fixation of the lap position with the locking pind = 4h8 x 20 DIN 7 fix spindle as well as linkage (d = 6mm) in horizontal position.Remove rubber bellow and ifnecessary the under it located filter pad. By means ofscrewdriver twist valve tappet so far, that neither a risein pressure occurs nor a drop in pressure. Alternativean adjustment at the linkage to axle 612 025 001is possible: loosen counternut and shift angles at theaxle bracket accordingly. Tighten counternut again.
Maintenance
If defects are noted during vehicle examinations or whendriving, then the unit should be exchanged. Whenworking with high pressure cleaners a distance of at least50 cm should be observed. Missing exhaust caps are tobe renewed.
Testing
Check function and leak - tightness of the unit. In the lapposition at the delivery ports 21, 22 neither rise ofpressure nor drop of pressure may result. Free move-ment and condition of the linkage is to be checked,bented or welded linkages are to be exchanged. Brittledor hardened rubber pieces are to be renewed.
Technical data
Operating pressure, dyn.: pe max. 13 barpermitted dyn.bellow pressure: pe max. 20 barOperating temperature: - 45°C to + 85°COperating range(charging - and exhausting): 45°Side of control: on the left and on the rightDead angle at 7 - 8 bar: 2°Port description: 1 = inlet port
2 = delivery port3 = exhaust
At twisting the control levers around 180° equal functionis reached like in drawn position within a tolerance of3,5°.
Symbol acc. to DIN ISO 1219
Assembling positions
round lever
at valve003 5757 09
at axle612 025 001
Linkages6
7
8
Attention - Dang er
The removal of the component may only be done with theair reservoirs drained.Attention: High pressures.
At settings no person should stay in the area of axlesand chassis.
Attention: Chassis is raising and lowering.
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10 - 17
6
9
9Versions
VERSION A
VERSION CI
Lap position adjusted to - 1° to - 3° at612 036 001 and 612 051 001/011
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11
VERSION CI
VERSION CII
12
13
VERSION D
VERSION D
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15
VERSION F
VERSION E16
17
18
19
Installation layout 612 0.. ...
Installation layout 612 04. ... with2nd drive height controlled by lift axle
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21
Installation layout 612 04. ... with 2nddrive height for different saddle heights
Air suspension system with side kneeling and 2nd drive height
Innovative Vehicle Technology000
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These installation instructions correspond to knowledge and experience atthe time of print and are subject to revision upon modification.Haldex does not accept any liability for applications exceeding the above-mentioned installation instructions.Special instructions are required inthese cases.
We reserve the right make modifications in respect of technical progress.Copying in extract from this document is only permissible with Haldexapproval.
AustriaHaldex Wien Ges.m.b.HViennaTel. +43-1 8 65 16 40Fax +43-1 8 65 16 40 27e-mail: [email protected]
BelgiumHaldex N.V./S.A.Zaventem(Brussels)Tel. +32-2 725 37 07Fax +32-2 725 40 99e-mail: [email protected]
BrazilHaldex do BrasilSao PauloTel. + 55-11 531 41 59 +55-11 531 49 99Fax +55-11 531 95 15e-mail: [email protected]
ChinaHaldex International Trading Co.Ltd.ShanghaiTel. +86-21 6289 44 69Fax +86-21 6279 05 54e-mail: [email protected]
FranceHaldex Europe S.A.Weyersheim (Strasbourg)Tel. +33-3 88 68 22 00Fax +33-3 88 68 22 09e-mail: [email protected]
GermanyHaldex Brake Products GmbHDenkendorf (Stuttgart)Tel. +49-711 93 49 17-0Fax +49-711 93 49 17-40e-mail: [email protected]
Haldex Brake Products GmbHHeidelbergTel. +49-6221 70 30Fax +49-6221 70 3400e-mail: [email protected]
Great BritainHaldex Ltd.Newton AycliffeTel. +44-1325 310 110Fax +44-1325 311 834e-mail: [email protected]
Haldex Brake Products Ltd.RedditchTel. +44-1527 499 499Fax +44-1527 499 500
PolandHaldex Sp.z.O.o.PraszkaTel. +48-34 350 1100Fax +48-34 350 1111e-mail: [email protected]
SpainHaldex Espana S.A.Parets del Valles (Barcelona)Tel. +34-93 573 10 30Fax +34-93 573 07 28e-mail: [email protected]
SwedenHaldex Brake Products ABLandskronaTel. +46-418 60 00Fax +46-418 60 01e-mail: [email protected]
South CoreaHaldex Korea Ltd.SeoulTel. +82-2 2636 7545Fax +82-2 2636 7548e-mail: [email protected]
USAHaldex Brake Products Corp.Kansas CityTel. +1-816 891 2470Fax +1-816 891 9447e-mail: [email protected]
www.brake-eu.haldex.com
The Haldex group is a worldwideoperating company that developsproducts for private cars, heavyand other commercial vehicles
with special emphasis on vehicle performance andsafety. The Haldex Group is quoted on the Stock-holm stock exchange.
