Air Braking Equipment for Towed Vehicles in Accordance with Council Directive 71/320/ EEC

Transcription

1 Air Braking Equipment for Towed Vehicles in Accordance with Council Directive 7/0/ EEC Diagrammatic Views and Description of Braking Systems and Air Braking Equipment. Edition This publication is not subject to any update service. New versions are available in INFORM at Copyright WABCO 00 Vehicle Control Systems An American Standard Company The right of amendment is reserved Version 00/07.0 Wabcodruck

2 Table of Contents Page. Graphic symbols. Identification of Port Connections 9. Recommendations for Installation for fitting standard braking systems to RREG. Description of Components 5 Please note: For Trailer ABS VARIO-C, see brochures For Vario Compact ABS VCS, see brochures and VCS II Trailer EBS, see brochure Trailer EBS D, see brochure

3 WABCO The right partner - to be on the safe side To bring safety to our roads - this has been WABCO s objective for decades. Through continuing technical innovations in the research, development and manu- facturing processes, we have today achieved a leading position in many market segments of pneumatic and electronic systems for commercial vehicles. Intelligent solutions for practical operation One example for the successful synthesis of the electronics and pneumatics sectors is WABCO s ABS braking system which has for years proved its worth in actual operation and which is being used by leading international manufacturers of commercial vehicles today. The drive-slip control system, ASR, is another feature which people have now come to expect in modern commercial vehicles. In the electronics sector, WABCO s product range also focuses on transmission controls, on air suspension systems (ECAS) for lorries and trailers, and on heating, air conditioning and ventilation controls. And in the mechanical/pneumatics sector WABCO has made a name for itself in compressed-air and air/hydraulic braking systems, compressors, door actuators and coupling controls. Success through international commitment WABCO forms an important part in a group of companies successfully operating all over the world. There are WABCO companies in Germany, Austria, Switzerland, France, the Benelux countries, Great Britain, Sweden, Italy, Spain and Brazil, and we are maintaining cooperating companies and joint ventures in Japan, India, and the USA. In addition to these interlinked companies, WABCO offers a comprehensive network of sales outlets and workshops. WABCO Service with a capital S A staff of close to 6,000 people ensure constant availability of service and proximity to our customers. This includes both the reliable supply with genuine WABCO spares for retro-fitting and repairs, and competent support and advice. And of course we also offer technical training on location. Our world-wide commitment has made us one of the leading firms in the industry. It is through the competence and dedication of our staff that WABCO today has a prominent position in the industry. A position which we intend to not only maintain but to strengthen further. With reliability, safety, quality and service, WABCO is your partner for the future.

4 . Graphic Symbols Graphic and functional symbols correspond with German Standards DIN 7 5, Mai 979 Edition, and DIN ISO 0, August 978 Edition. The graphic symbols (DIN 7 5) can be used for diagrammatic views of braking systems (plans of installation) in motor vehicles. The connections at the symbols have been marked in accordance with DIN ISO 6786, December 98 Edition. These markings are not strictly part of the symbols but can be used additionally for the purpose of clarification. The functional symbols (DIN ISO 9) are designed to show the internal functions of the units or parts thereof. They consist of one or more basic symbols and normally of one or more functional symbols. In circuit diagrams, the units are shown in their off position or in the neutral position of the control. If this is not the case, this is mentioned specifically (e. g. operating position). Please note: The graphic and functional symbols shown on Pages 5 to 8 are extracted from the respective DIN Standards. Only those symbols required for towed vehicles are shown.

5 Basic Symbols. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Flow line Marking of flow line Direction (of flow and the nature of the fluid) Pneumatic flow or exhaust to atmosphere) Hydraulic flow line Elektric flow line Pipeline junctions: Connected Crossed pipelines, not connected Types of flow line: Looped line Flexible hose, usually connecting moving parts (brake hose) Coiled line R (Wendelflex ) Diminished cross section in the line (restriction) Circle as a symbol forcompressors, pumps, motors, measuring instruments, mechanical links, rollers, etc. 5

6 . Basic Symbols Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Rectangle and square as a symbol for valves, cylinders and actuators Diamond for conditioning apparatus (filter, lubricator separator, heat exchanger) Enclosure for several components assembled in one unit Arrow, indication of: Direction of flow Direction of rotation Path and direction of flow through valves Sloping arrow: Indication of the possibility of a regulation Actuating mechanisms Levers, shafts, piston rods and mechanical connections Detent: A device for maintaining a given position Muscular control: by push button, by lever or by pedal (general symbol) Rotating Via linkage 6

7 Basic Symbols. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Muscular control: by lever by pedal Control: pneumatic hydraulic by different control areas The control paths are inside the unit Examples for multiple control: double control by release of pressure by application of pressure triple control ) Electrical control, by solenoid valve Slack adjuster: manual automatic Warning facilities Pressure measurements: Pressure gauge ) The flash arrow ( ) is not part of the symbol 7

8 . Basic Symbols and Valves Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Dual pressure gauge Low pressure indicator ) Lamp Buzzer Test and filling coupling Test and filling coupling: in a line on the apparatus on the apparatus with subsequent mechanical actuator Filling coupling: Energy take off is not possible As a rule, a single square is to be used to represent the valves Directional control valve with manual control ) The flash arrow ( ) is not part of the symbol 8

9 Valves. Graphic Symbols in accordance with DIN 7 5 ) Functional Symbols in accordance with DIN ISO 9 Description Non return valve ) Non return valve with limited return flow ) Non return valve with restricted return flow (Throttle check valve) Alternating valve without return flow (Double check valve) Alternating valve with return flow (Shuttle valve) Choke valve Rapid exhaust valve ) Pressure ratio valve, not regulating at a constant ratio (Regulating valve) ) In operating function, the direction of flow is shown here to be from left to right. 9

10 . Valves Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description ) Regulating at a constant ratio (Pressure reducer) ) Pressure relief valve: without return flow with return flow with limited return flow Double relief valve with limited return flow Air suspension valve: with one bellows connection with two non equivalent bellows connections ) see Page 9 0

11 Valves. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Drain valve (Water trap): with manual control, in continuous line with manual control, on reservoir automatically drained automatically drained with impulse control ) Safety valve ) Relay valve: with pressure reduction with electro-magnetically controlled brake valve and pressure limiting device (Solenoid relay valve) ) see Page 9

12 + --. Valves + -- Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description + -- Solenoid control valve ) + -- Brake valve, electro magnetically controlled, with pressure limiting device Empty / Load valve Automatic load-sensing valve: mechanically controlled with pneumatic or hydraulic control, e. g. single-circuit pneumatic control mechanically controlled with integral relay valve ) see Page 9

13 Valves. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description - - Relay emergency valve for a single-line braking system: without release valve - - with release valve () - - with manually adjustable pressure limiting valve, e. g. with three () present pressure values - - with release valve and manually adjustable pressure limiting valve without stipulation of the number of preset pressure values - - Relay emergency valve for a dual-line braking system: without release valve, with adjustable lead

14 . Valves Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description ) - Relay emergency valve for a dual-line braking system: - with release valve and adjustable lead - - with manually adjustable pressure limiting valve without stipulation of the number of preset pressure values - () - with release valve and manually adjustable pressure limiting valve, e. g. with three () preset pressure values ) Pressure limiting valve: with one unlimited relief port () and one limited relief port () () manually controlled, e. g. with three () preset pressure values ) see Page 9

15 Cylinders. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description General pneumatic actuator: (also brake chamber) single circuit dual circuit with locking mechanism Telescopic cylinder Double acting cylinder General hydraulic cylinder: single circuit master cylinder, mechanically actuated dual-circuit master cylinder, mechanically actuated slave cylinder, single-circuit 5

16 . Cylinders Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Hydraulic master cylinder: dual-circuit General spring brake actuator: pulling, with release mechanism at front pushing, with release mechanism at rear Combination brake actuator: pushing, pneumatically actuated with release mechanism at rear pushing, pneumatically and hydraulically actuated Servo-cylinder with hydraulic master cylinder 6

17 Reservoirs, Filters and Shut Off Valves. Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description General reservoir for energy storage (pressure reservoir) Single-chamber air reservoir Multi-chamber air reservoir Accumulator Fluid reservoir for compensation, anti-freeze and hydraulic fluids General filter Suction filter Line filter Shut off valve: without pressure release with pressure release 7

18 . Hose Couplings, Switches, Other Accessories Graphic Symbols in accordance with DIN 7 5 Functional Symbols in accordance with DIN ISO 9 Description Quick acting coupling: uncoupled, with open end uncoupled, closed by free non-return valve closed by free non-return valve and two connections Quick acting couplings, connected Dummy coupling connected Blind coupling ) Electric switch: Make contact, mechanically actuated Make contact, pneumatically actuated Break contact, pneumatically actuated Air suspension Exhaust ports: Air bleed Exhaust to atmosphere plain with no provision for connection threaded for connection Elastic equilizing arm (Flexible arm) ) The flash arrow ( ) is not part of the symbol 8

19 Identification of Port Connections. On Units in Air Braking Systems in accordance with DIN ISO 6786 For marking the port connections of units of compressed air braking systems, a standards sheet was compiled in the FAKRA and in the ISO which was published in December, 98 as a Standard under number DIN ISO This Standard contains DIN 7 5, Edition, into which the International Standard ISO 6786, Edition was incorporated without any alterations. We are already gradually introducing these new markings, initially for new designs and when making replacement casting moulds. The main characteristics of the Standard are that the connections on the unit are expressed in figures and not in letters. The reason for this is to prevent letters being misinterpreted in other countries. are not to be numbered consequtively but that the identification digits of the connection provide information on the funcion of the unit's connection. The identification code consists of a one or two digit number. The first digits mean: 0 Suction connection Energy supply Energy delivery (not to atmosphere, see Digit ) Exhaust Pilot connection (entry into unit) 5 Spare A second digit may be added when several similar port connections are available, for example in the case of split systems. The function represented by this second digit is left to the discretion of the vehicle manufacturer but should start at and continue consecutively, for example,,, etc. Exceptions are permitted when applying the building block principle. The following codes are not available for free choice: 7 Anti-freeze inlet 7 Anti-freeze outlet 8 Lubricating oil inlet 8 Lubricating oil outlet 9 Cooling liquid inlet 9 Cooling liquid outlet If there are a number of similar connections belonging to one unit and intended to fulfil the same function, they shall have the same designation. A connection which can fulfil, in any one application, more than one function, shall be identified by two (first) digits. These shall be separated by a dash (see example on next page). A connection which can fulfil more than one function in different applications shall be identified in accordance with agreement between the manufacturer and the customer (for example multiway valves). The digits designated shall be placed close to the ports on the units and can also be placed in the braking system diagram next to the identified line connections. They apply to air braking systems in motor vehicles, including those in which the transfer is in part hydraulic, and their towed vehicles. 6 Spare 7 Anti-freeze liquid connection 8 Lubricating oil connection 9 Cooling liquid connection } for compressor 9

20 . Identification of Port Connections As an example, DIN ISO 6786 shows an unloader valve with filling and switching connections. In this example, the references signify: Energy supply from the compressor - Energy supply using a valve for filling the air braking system, and energy delivery by use of a valve as used for inflating tyres Connection to atmosphere (venting) Energy delivery to the energy accumulator (air reservoir) Energy delivery (switching connection) 0

21 . Standard Braking-Systems Please note: Further schematics are contained in brochure Vario Compact ABS (VCS) System Suggestions Publication No

22 Recommendations for Installation for fitting standard braking systems to RREG Overview a) Braking Systems with Vario Compact ABS Page -Axle Trailers Axle Trailers Axle Semi-trailers Axle Semi-trailers Axle Semi-trailers Axle Semi-trailers Axle Semi-trailers Note: Central axle trailers are treated the same as semi-trailers. For further schematics, see brochure VCS System Overview Wabco Publication No b) Additional Equipment Air suspension systems for Trailers Air suspension systems for Semi-trailers Air suspension systems with lifting axle and overload protection Lift Axle Control Council Directive 7/0/EEC of the European Communities and ECE Regulation are contained in the manual entitled Vehicle Regulations ( Fahrzeug Vorschriften ). This manual is available from our Department AM-M, Tel. (5) quoting Part Number

23 Trailers Braking Diagram Axle. Dual line air braking system with ABS S / M: Supply Line, red Control Line, yellow x) Table: Types of load sensing valves used from the air suspension bellow Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve 7 X) see Table ***** ***** 0 8, * S x S x 5, *** X) see Table, 5 *, *, 5 * ***** Supplied by Axle Manufacturer **** An opposed piston ABS relay valve can be used instead. *** To be fitted if required ** If used, items 8 (x), 9, are dispensable. * not applicable for disk-brakes 9 Wiring Diagram: see **** 8 **** S x 9 S x 0 *** COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve ** ***** to the brake chamber(s) ***** No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Brake Chamber Mounting pack * Tristop spring brake actuator Mounting pack * Relay emergency valve Adaptor valve No. Pcs. Description Part Number 8 Pressure limiting valve *** Two-way valve Quick release valve Test connection Test connection Test connection Test connection Dummy coupling with mount ABS parking socket, volts ABS plug with cable, volts ABS relay valve, volts **** Y-Solenoid cable, RA Solenoid cable, FA ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

24 -Axle Braking Diagram Trailers Supply Line, red 8 Control Line, yellow x) Table: Types of load sensing valves used from the air suspension bellow - 0 Dual line air braking system with ABS S / M: Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve 9 8 ***** X) see Table *****, * S x 9 S x 7 5, 6 9 *** 5, 6 * X) see Table 0 5, 6 * 5 S x 9**** 5, * 5, 6 * 5, 6 * ***** Supplied by Axle Manufacturer **** An opposed piston ABS relay valve can be used instead. *** To be fitted if required ** If used, items 9 (x), 0, are dispensable. * not applicable for disk-brakes Wiring Diagram: see **** *** S x 5 COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve 5 ** to the brake chamber(s) ***** ***** No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Link for ALV Brake Chamber Mounting pack Tristop spring brake actuator Mounting pack * Relay emergency valve No. Pcs. Description Part Number 8 Adaptor valve Pressure limiting valve *** Two-way valve Quick release valve *** Test connection Test connection Test connection Test connection Dummy coupling with mount ABS parking socket, volts ABS plug with cable, volts ABS relay valve, volts **** Y-Solenoid cable, RA Solenoid cable, FA ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

25 Semi-trailers Braking Diagram Axle. Dual line air braking system with ABS S / M: Supply Line, red Control Line, yellow 0 **** x) Table: Types of load sensing valves used from the air suspension bellow For brake chambers 0 supply lines of ABS relay valves at Port relay emergency valve X) see Table 5, *** *** 9 S x 5, * S x 9, * 6 **** ***** ***** Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve ***** Supplied by Axle Manufacturer **** To be fitted if required *** An opposed piston ABS relay valve can be used instead ** If used, items Pos.,, are dispensable. * not applicable for disk-brakes COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve Wiring Diagram: see ** to the brake chamber(s) No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Tristop spring brake actuator Mounting pack * 90 5 No. Pcs. Description Part Number Relay emergency valve Two-way valve Quick release valve **** Test connection Test connection Test connection ABS electrical helix, volts**** ABS socket with cable, volts ABS relay valve, volts *** Y-Solenoid cable ABS electronics, volts Extension cable for sensor ABS ECU compact arrangement **

26 . -Axle Braking Diagram Semi-trailers Dual line air braking system with ABS S / M Supply Line, red X) 9 5, S x 7 0 ***, * S x ***** 6, * S x 0 ***** Control Line, yellow **** x) Table: Types of load sensing valves used from the air suspension bellow Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve see Table 5 *** 0, * ***** Supplied by Axle Manufacturer **** To be fitted if required *** An opposed piston ABS relay valve can be used instead ** If used, items Pos.,, 5 are dispensable. * not applicable for disk-brakes S x S x 6, * 7 **** S x 7 ***** ***** COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve Wiring Diagram: see ** to the brake chamber(s) No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Link for ALV Tristop spring brake actuator Mounting pack * 90 5 No. Pcs. Description Part Number 5 Relay emergency valve Two-way valve Quick release valve **** Test connection Test connection Test connection ABS electrical helix, volts*** ABS socket with cable, volts ABS relay valve, volts *** Y-Solenoid cable ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

27 Semi-trailers Braking Diagram Axle. Dual line air braking system with ABS S / M Supply Line, red Control Line, yellow see Table x) Table: Types of load sensing valves used from the air suspension bellow Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve ***** Supplied by Axle Manufacturer **** To be fitted if required *** An opposed piston ABS relay valve can be used instead ** If used, items Pos. 5, 6, 7, 8 are dispensable. * not applicable for disk-brakes Wiring Diagram: see COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve ** to the brake chamber(s) No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Link for ALV x) Tristop spring brake actuator Mounting pack * Relay emergency valve No. Pcs. Description Part Number 6 Two-way valve Adaptor valve **** Quick release valve **** Test connection Test connection Test connection Test connection ABS electrical helix, volts **** ABS socket with cable, volts ABS relay valve, volts *** Y-Solenoid cable Solenoid cable ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

28 . -Axle Braking Diagram Semi-trailers Dual line air braking system with ABS S / M - Supply Line, red - 6 Control Line, yellow - 9 X) see Table 0 7 5, ***** 5, * 0 *** *** S x, 5 * S x 8 ****, 5 * 8 ***** **** x) Table: Types of load sensing valves used from the air suspension bellow 7, 5 * ***** S x S x, *, 5 * ***** Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve ***** Supplied by Axle Manufacturer **** To be fitted if required *** An opposed piston ABS relay valve can be used instead ** If used, items Pos., 5, 6 are dispensable. * not applicable for disk-brakes Wiring Diagram: see COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve 9 ** to the brake chamber(s) No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Brake Chamber Mounting pack Tristop spring brake actuator No. Pcs. Description Part Number 5 Mounting pack * Relay emergency valve Two-way valve Quick release valve **** Test connection Test connection Test connection ABS electrical helix, volts **** ABS socket with cable, volts ABS relay valve, volts *** Y-Solenoid cable ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

29 Semi-trailers Braking Diagram Axle. Dual line air braking system with ABS S / M Supply Line, red Control Line, yellow - **** x) Table: Types of load sensing valves used from the air suspension bellow X) see Table 5, ***** ***** 7, * 6 ***, * S x 6 *** S x, 5 *, 5 * 8 ****, 5 * 9 **** 6 *** 8, 5 * S x S x ***** ***** Try to achieve: Equal dead-centre volumes of all brake chambers plus allocated brake hoses starting from one ABS relay valve ***** Supplied by Axle Manufacturer **** To be fitted if required *** An opposed piston ABS relay valve can be used instead ** If used, items Pos. 6, 7, 8, 9 are dispensable. * not applicable for disk-brakes Wiring Diagram: see COMPACT ARRANGEMENT to air reservoir to port load-sensing valve or relay emergency valve ** to the brake chamber(s) No. Pcs. Description Part Number Hose coupling, supply Hose coupling, control Line filter Double release valve Air reservoir Mounting clamp Drain valve Load sensing valve with integral knuckle joint x) Load sensing valve with integral test vave x) Plate, ALV setting air x) Plate, ALV setting mech. x) Brake Chamber Mounting pack Tristop spring brake actuator Mounting pack * Relay emergency valve No. Pcs. Description Part Number 7 Two-way valve Quick release valve **** Adaptor valve Test connection Test connection Test connection Test connection ABS electrical helix, volts **** ABS socket with cable, volts ABS relay valve, volts *** Y-Solenoid cable Solenoid cable ABS electronics, volts Extension cable for sensor Extension cable for sensor ABS ECU compact arrangement **

30 Air Suspension System for Trailers Air suspension bellows 8 8 Supply from the service braking system 7, 6, Automatic loadsensing valve Automatic loadsensing valve 8 No. Pcs. Description Part Number Charging valve without backflow 6.0 bar Air reservoir Drain valve Test connection No. Pcs. Description Part Number 5 Line filter Mounting clamp Levelling valve Test connection for Trailers (lifting and lowering) Air suspension bellows 8 8 Supply from the service braking system 9, 6 5, Automatic loadsensing valve Automatic loadsensing valve 7 8 No. Pcs. Description Part Number Charging valve without backflow 6.0 bar Air reservoir Drain valve Test connection No. Pcs. Description Part Number 5 Line filter Mounting clamp Levelling valve Test connection Rotary slide valve

31 Air Suspension System for Semi-trailer Air suspension bellows 8 Supply, 7 from the service braking system Automatic loadsensing valve No. Pcs. Description Part Number Charging valve without backflow 6.0 bar Air reservoir Mounting clamp Line filter No. St. Description Part Number 5 Drain valve Test connection Levelling valve Test connection for Semi-trailer (lifting and lowering) Air suspension bellows 8 Supply, 9 from the service braking system 5 6 Automatic loadsensing valve 7 8 No. Pcs. Description Part Number Charging valve without backflow 6.0 bar Air reservoir Mounting clamp Line filter No. Pcs. Description Part Number 5 Drain valve Test connection Levelling valve Test connection Rotary slide valve

32 Lift Axle System Lift Axle Control Valve solenoid raise / automatic lower Suspension bellows Plastic pipe x,5 Alternative 0 x Lift bellows 5 9 * * 6 0 II I Test valve * * optional 8 No. Pcs. Description Part Number Charging valve Air reservoir Line filter Air reservoir Lift axle control valve No. Pcs. Description Part Number 6 Pressure limiting valve Pressure switch Test connection Switch 0 Levelling valve Lift Axle Control Valve solenoid raise / automatic lower Suspension bellows Plastic pipe x,5 Alternative 0 x Lift bellows 5 * * 6 0 II I Test valve 8 * * optional 7 No. Pcs. Description Part Number Charging valve Air reservoir Line filter Air reservoir No. Pcs. Description Part Number 5 Lift axle control valve Pressure limiting valve Pressure limiting valve Levelling valve

33 Lift Axle System Fully automatic raise and lower Suspension bellows Plastic pipe x,5 Alternative 0 x Lift bellows 5 * * 6 0 Test valve 8 * * optional 7 No. Pcs. Description Part Number Charging valve Air reservoir Line filter Air reservoir No. Pcs. Description Part Number 6 Lift axle control valve Pressure limiting valve Test connection Levelling valve Fully automatic raise and lower with /- directional control valve Suspension bellows Plastic pipe x,5 Alternative 0 x Lift bellows 5 * * Test valve 8 * * optional 7 9 No. Pcs. Description Part Number Charging valve Air reservoir Line filter Air reservoir Lift axle control valve No. Pcs. Description Part Number 6 Pressure limiting valve Test connection Levelling valve / Directional control valve Throttle Ø,5 mm

34 Lifting axle control EBS D Full automatic with traction help and single circuit lifting axle valve and residual pressure control Suspension bellows Diagnosis = N. C. = GND = Signal / Eingang Lift bellows black - Input brown GND not be connected switching to plus from the service braking system switching to minus * optional Plastic pipe x.5 or 0 x Pay attention to parameters please consider ISO 098 wiring please consider truck wiring Lifting axle circuit T - EBS D Button traction help: press less than 5 sec. = start traction help press > 5 sec. = constrained lowering Control independend from truck No. Pcs. Description Part Number Charging valve with backflow Pressure limiting valve Lifting axle valve Raise/Lower valve Levelling valve Charging valve without backflow No. Pcs. Description Part Number 7 Air reservoir Trailer modulator Diode (eg. Wehrle) 0 Cable Diagn. + ISS / ILS-cable /-Way Solenoid valve

35 . Description of Components 5

36 . Overview page Brake Chamber Line Filter Knuckle Joint 06 6 Linkage for Levelling Valve 0 8 Check - Valve 0 9 Charging Valve Two-Way Valve 08 5 Pressure Switch 009 / 0 5 Accessories for Hose Couplings Shut-Off Cock Duo-Matic Quick Coupling Raise/Lower Valve Release Valve /-Directional Control Valve Lift Axle Control Valve Test Coupling Levelling Valve /-Way Solenoid Valve 7 0 / 7 / 7 8 /-Way Solenoid Valve 7 7 / 70 / 7 8 Pressure Reducing Valve Quick Release Valve Pressure Limiting Valve Outline Load-Sensing Valves for Trailers Load-Sensing Relay Emergency Valve Load-Sensing Valve (ALV) Load-Sensing Valve (ALV) Load-Sensing Relay Emergency Valve Indicator Plate Load Sensing Device Settings PC Service for Settings of the Load-Sensing Device 6 Load-Sensing Valve Tristop Spring Brake Actuator 95.. /.. 0 Drain Valve Air Reservoir Hose Coupling / 0 Release Valve / Height Limiting Valve Relay Emergency Valve Relay Valve / 0 56 Quick Release Valve Adapter Valve Adapter Valve

37 Brake Chamber 000. for Disc Brake Purpose: To generate the braking force for the wheel brakes. It can also be used for other purposes, e. g. clamping, lifting and actuating. Operation: When the pressure from port (A) or (B) acts upon diaphragm (b), the diaphragm and piston (a) move to the right. The resulting piston force is transmitted through push rod (c) to the brake lever (slack adjuster) and then to the wheel brakes. When the actuator is exhausted, spring (d) causes piston (a) and diaphragm (b) to return to their unapplied position. The diaphragm actuator force depends on the diaphragm load pressure and on the effective diaphragm surface area which varies with the amount of curvature in the diaphragm (b). Maintenance: No maintenance is necessary beyond the tests required by law. However, even if working satisfactorily (no leakages, response pressure not exceeding 0.5 bar), the brake chamber should be removed, disassembled, cleaned, wearing parts replaced, and then reassembled at least every two years. 7

38 . 000 Brake Chamber Installation Requirements: The diaphragm should be installed with the link joint slanting downwards so that any water that is splashed into the unit can drain out. unapplied position, the spring in the unit must push the piston and the diaphragm against the housing (see installation schematic). When installing the brake chamber, care should be taken that the brake line is not positioned lower than the actuator unit. This prevents damage to the brake line caused by ground scraping. To facilitate correct line installation, the diaphragm actuator is provided with two connecting ports, either of which can be used by repositioning the screw plug. When installing the actuator or when adjusting the brakes, the push rod must not be pulled out. In the It is also important that the push rod is not pulled out when actuating a mechanical parking braking system which is also connected to the brake lever since this could cause damage to the actuator parts. One way to prevent the push rod being pulled out is to use the diaphragm actuator with a slotted link joint rather than with a roundhole link joint. This provides the equivalent of at least a twothirds maximum diaphragm actuator stroke for separate actuation of the parking braking system. Note: If the brake chamber is fitted vertically on steering dummy axles (piston rod pointing upwards), the sealed version is recommended by axle manufacturers: Part Number 0" " } with Mounting Kit 6" without Mounting Kit Installation schematic: Unapplied position must have no clearance between piston and diaphragm Operating position at one half of maximum Sections and also apply (fitting and mounting) of the installation instructions for Tristop spring brake actuators, see Page. *) can be supplied by the axle manufacturer. 8

39 Brake Chamber 000. Installation: Dim. X = theoretical pivot point of push rod when retracted ) fording ability: exhaust pipe and gaiter Type Dimensions in mm D D G H L L L L L5 L6 R R R X α M x M x ) 5 66 M6 x M6 x M6 x M6 x M6 x Technical Data: Part Number Type Stroke max Displacement at / stroke in litres Torque in Nm A B C Mounting Kit ) ± ± ) ) ± ± ) ) ) ± ± ) ) ± ± ± ± ) ± ± 5.5 Weight in kg.5.8 ) without link joint ) Brake Chamber Type 6 (Thread of pipe connection M x.5) is supplied complete with fastening nuts and screw plug but without the link joint (part number see Page ). ) Brake Chamber is supplied with Mounting Kit 9

40 . 000 Brake Chamber Technical Data: Operating pressure Permissible medium Operating temperature range Push rod pivot angle 8.5 bar max. Air - 0 C to + 80 C Z: all directions Installation: Dim. X = theoretical pivot point of push rod when retracted Round-hole link joint Slotted link joint Thread Adapter: D = M x D = M6 x.5 Dimensions in mm Type D D G H L L L L L5 L6 R R R X α 9 5 M x M x M x M6 x M6 x M6 x

41 Brake Chamber 000. Technical Data: Part Number Type Stroke max Displacement at / stroke in litres Torque in Nm Part Number for Mounting Kit A B C Round-hole Slotted Weight in kg * ± * ± ± ± ± ± ± ± ± ± ± * with bellows Mounting Kit for Brake Chamber: The following mounting kits are available on request: Part Number: Mounting Kit No. Description Part Number Screw Plug M6 x Packing A6 x M Hexagon Nut M x M6 x Hexagon Nut M x M6 x Link Joint with M6 x Bolt Ø M x Bolt Link Joint with Bolt Ø M6 x M x M x x 5 x x 5 x x 5 x Disk Splint x

42 . 000 Brake Chamber Characteristics of Brake Chambers Types 9 to 0 Th A = medium piston force: This is the piston force which is established through an integration of between / and / of total piston stroke (s max ). s p = usable piston stroke: This is the stroke at which piston force Th is 90% of medium piston force Th A. Type Th A (N) = s p (mm) s max (mm) x p x p x p x p x p x p x p x p x p x p x p x p Medium piston force ThA in kn Type Input pressure in bar Usable piston stroke Sp in mm Input pressure in bar

43 Brake Chamber for disk brakes 000. Installation: in mounted position lower breather hole ± 0 ** out of plane Stroke permissible installation position Part Number Type Dimensions in mm Port D D L L L L L5 R a A B x ) x x ) x ) x x x x x x x x x ) ) x ) with screw plug M6 x.5 ) 57 mm Stroke permissible installation position Technical Data: Type Deflection of the push rod Stroke max. Displacement at / stroke in litres [at 6 bar] Operating pressure max. 57 mm bar Operating temperature range 6 57 mm bar. 8 max. 8 6 mm bar.8-0 C bis + 80 C 0 at 0 mm Stroke 6 mm bar.8 6 mm bar.0 6 mm bar.0 Weight in kg.

44 . 000 Brake Chamber for disk brakes Test results for brake cylinder for disk brakes type to Th A = medium piston force: This is the piston force which is established through an integration of between / and / of total piston stroke (s max ). s p = usable piston stroke: This is the stroke at which piston force Th is 90% of medium piston force Th A. Typ Th A (N) = s p (mm) s max (mm) 86p -55.0p p p p - 0.9p p p p p p p Fitting instruction for disk brake cylinders for trailers The cylinder must be fitted horizontal Permissible deviation: 0 with push rod showing upward and 0 showing downwards.. The open drain/breather hole must point downwards. Max deviation +/- 0 It is essential to remove the plastic plug.. With tristop cylinders, the the connecting line between service brake and spring box must be fitted in the area of the cylinder's upper part.. Fastening To fix the cylinders, use nuts M 6x.5 property class 8 (WABCO Nr ). Tighten both nuts by hand until Cylinder has plane contact. Tighten both nuts with 0 N. Tighten both nuts with torque key to 0 Nm (tolerance 0Nm). Using self-securing nuts, the torque must be raised appropriately 5. The push rod must join the flattened dome of the brake lever. 6. Flange area and sealing surface of cylinder and disk brake must be clean and undamaged. The gaiter must have no damages and together wit the back-up ring, being proper seated. 7. After fitting the tristop cylinder, the release screw must be screwed to the driving position (torque with Nm).

45 Line Filter 500. Purpose: To protect the air braking system against dirt. Operation: The compressed air reaching the line filter via port passes through the filter cartridge in which any particles of dirt are retained; the compressed air is cleaned before it reaches any downstream appliances from port. If the line filter is blocked, the filter cartridge is pushed upwards against the force of the pressure spring and the compressed air will pass through the line filter without being cleaned. If port is exhausted while the filter cartridge is blocked, the pressure in port can push the cartridge downwards against the force of the compression spring. This permits return flow from port to port. Maintenance: The frequency for cleaning the filter depends largely on the operating conditions and is normally approx. every to months. Remove the filter cartridge and blow through with compressed air. Damaged filter cartridges need to be replaced. Installation Requirements: The filter is placed in the piping system without being fastened. Make sure that there is sufficient space for removing the filter cartridge (see Installation ). Technical Data: Part Number Operating pressure 0 bar max. Free passage Ø mm =.cm Thread of pipe connections G = M x.5 G = M6 x.5 Pore size of Filter 80 to 0 µm Permissible medium Air Operating temperature range - 0 C to + 80 C Weight 0.9 kg Installation: Port connections: = Energy supply = Energy delivery *) Space required for removing filter cartridge 5

46 . 06 Knuckle Joint Purpose: To prevent damage to the automatic load sensing valve. Operation: In the event of large axle movements in excess of the range of movement of the automatic load sensing valve, arm (e), which is horizontal while at rest, is deflected about a fixed point in housing (c). Pressure springs (a) and (b) exert pressure on ball (d) providing constant tensional contact with housing (c) until arm (e) again returns to its normal horizontal position where it is again in full contact with the front face of the housing. Deformation of the connecting linkage to the automatic load sensing valve is prevented by a ball joint (f) attached to arm (e). Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The selected knuckle joint must be such that any travel exceeding the operating range of the load-sensing valve is no greater than the permissible deflection (h). Deflection values for single and tandem trailer axles are shown in the graph below: The knuckle joint is mounted on the single axle or between the axles of the tandem axle unit, taking care to follow the axle manufacturer's specifications. The knuckle joint is arranged in such a way that its ball joint is located at the neutral point of the axle(s). The neutral point is the point which is not subject to any influence from either:. Torsional movement of the axle during the braking process, or. Drifting in bends in the case of steerable axle units, or. One-sided axle load due to uneven road surfaces. Proper positioning of the knuckle joint ensures that only changes in the axle load (both static and dynamic) will effect adjustment of the automatic load-sensing valve. The knuckle joint is connected to the control lever of the automatic load sensing valve by means of a rod (M8 thread) and a hex nut (M8, DIN 9), neither of which are included in the pack. The length of this rod depends on the individual installation of the appliances in the vehicle. fmax = maximum spring deflection in accordance with axle manufacturer's specifications Depending on the existing connection for the connecting rod on the control lever of the automatic load sensing valve to be used, the connecting rod is left smooth or 6

47 Knuckle Joint 06. threaded (M8) for a total length of approx. 5 mm. This thread takes a hexagon nut M9 DIN 9. The other end is screwed into the ball joint and secured by means of the hexagon nut. In order to prevent damage to the flexible rubber connections, the smooth ends need to be carefully deburred. Technical Data: Part Number Length L in mm Deflection h in mm Deflection force in N F F Installation: 7

48 . 0 Linkage Purpose: To provide a flexible connection for the linkage of Levelling Valve Installation Requirements: rubber sleeves (adjusting lever for levelling valve and linkage) is not included and needs to be cut to length by the user (please also refer to the section on Levelling Valve, Page 75). Fit a flat bar for mounting the linkage to the vehicle axle in question. The pipe required for connecting the two Installation: Part Number:

49 Check - Valve 0. Purpose: To protect the pressurized lines against unintentional venting. Operation: Air can only pass in the direction indicated by the arrow. Return flow of the air is prevented by the check valve closing the inlet in the event of a drop in pressure in the supply line. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The Check Valve can be fitted in any position within the piping system. Look out for the arrow on the housing which indicates the direction of air flow. Symbol A Symbol B When the pressure rises in the supply line, the springloaded check valve again opens the passage which results in an equalization of pressure. Technical Data: Operating pressure 0 bar max. Nominal diameter Ø 8 mm Thread of pipe connections M x.5 Permissible medium Air Operating temperature range - 0 C to + 80 C Weight 0.7 kg Part Number Symbol Comments A B constant throtting Ø mm B constant throtting Ø 0.5 mm Installation: 9

50 . 00 Charging Valve with return flow without return flow Purpose: Charging Valve with return flow The passing of compressed air to second air brake reservoir only when the rated pressure for the system in the first reservoir has been reached. If the pressure in the first reservoir falls below that of the second reservoir there is a feedback supply of air from the second reservoir. Charging Valve without return flow The passing of compressed air to auxiliary equipment (e. g. door actuation, auxiliary and parking braking systems, servo clutch, etc.) only when the rated pressure for the braking system has been reached in every air reservoir. Charging Valve with limited return flow The passing of compressed air to other consumers (e. g. auxiliary and parking braking systems) only when the rated pressure for the braking system has been reached in all reservoirs. Also the protection of pressure for the motor vehicle in the event of the trailer's supply line failing. If the pressure in the air reservoirs of the service braking system drops, part of the compressed air will return until the closing pressure (which is dependent on the opening pressure) is reached Operation: With all charging valves, the compressed air passes in the direction of the arrow into the housing and through port (g) under diaphragm (d) which is pressed into its seat by adjusting spring (b) and piston (c). When the charging pressure has been reached, the force of the adjusting spring (b) is overcome so that the diaphragm (d) is lifted from its seat, opening port (e). The air flows directly or after opening of non-return valve (h) to the reservoirs or consumers in the direction of the arrow. Charging valves with return flow allow the compressed air to flow back from the second reservoir after the opening of check valve (f) if the pressure in the first reservoir has dropped by more than 0. bar. In the case of charging valves without return flow, return flow is not possible since non-return valve (h) is kept closed by the higher pressure in the second reservoir. Charging valves with limited return flow allow the air to flow back until the closing pressure of diaphragm (d) is reached. When this is reached, adjusting spring (b) presses diaphragm (d) into its seat via piston (c), thus preventing any further pressure compensation in the direction opposite to the direction of the arrow. The charging pressure can be adjusted on all types by turning adjusting screw (a). Turning clockwise increases charging pressure, turning anti-clockwise has the opposite effect. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The charging valve can be mounted in the piping system in any position. Take care to observe the arrow on the housing indicating the charging direction. with limited return flow 50

51 Charging Valve 00. Technical Data: Operating pressure bar max. Nominal diameter Ø 8 mm Thread of pipe connections M x,5 Permissible medium Air Operating temperature range - 0 C to + 80 C Weight 0.5 kg Part Number Valve Type Charging pressure setting in bar (Tolerance minus 0.) Charging valve with return flow Charging valve without return flow * 00 0 Charging valve with limited return flow 5.0 * * * Closing Pressure = Charging Pressure 5 % Installation: Port connections: = Energy supply = Energy delivery 5

52 . 08 Two-Way Valve Purpose: To alternately pressurize or exhaust a line which can be controlled by two different lines or circuits. Operation: The two circuits are connected to ports and, and the brake unit to be supplied is connected to port. When air is delivered into either of ports or, the pressure forces piston (a) against the inner seat on the opposite port or. Thus, the circuit that is not actuated is closed and air flows through port to the connected unit. As soon as the pressure of the actuated circuit drops or is interrupted and the pressure in the opposite circuit is greater, piston (a) moves in the opposite direction. Compressed air will then flow from that circuit to the brake unit. In Version 050, an integral pressure spring pushing against piston (a) causes priority to be given to port over port. This means that a reduction in pressure is always effected via port. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The two-way valve is installed with ports and in a horizontal position (DIN 7 ). Symbol A Symbol B Technical Data: Part Number Symbol A A B Operating pressure 0 bar max. Dimension: L 76 mm 9 mm Nominal diameter Ø mm Ø 0.5 mm Thread of pipe connections G = M x.5 - deep G = M6 x.5 - deep Permissible medium Air Operating temperature range - 0 C to + 80 C Tightening torque 5 Nm max. Weight 0.5 kg 0.9 kg 5

53 Two-Way Valve 08. Installation: shown: Port connections: = Energy supply = Energy supply = Energy delivery shown:

54 . 009 Pressure Switch Purpose: The pressure switch is used to switch on or off electrical units and lamps. Operation: Circuit Closer When the rated pressure set at the switch is reached, diaphragm (c) is raised, closing contact plates (b). Contact plates (b) will open again when the pressure drops. Circuit Breaker When the rated pressure set at the switch is reached, diaphragm (e) is raised, opening contact plates (d). pressure values can be adjusted within a certain range by means of adjusting screw (a). Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: Depending on the type of switch used, the single-pole pressure switch can be fitted either anywhere in the pressure pipe or directly in an appliance. Switches of Type I are fastened using a screw M8, ensuring proper earth contact. The connecting cable needs to be fitted with a cable ear. Contact plates (d) will close again when the pressure drops. To adapt either switch for various types of operation, the response Circuit Closer Circuit Breaker 5

55 Pressure Switch 009. Technical Data: Part Number Operating pressure Breaking pressure Thread of pipe connections Type of protection in accordance with DIN Operating voltage (DC) Electrical breaking capacity under inductive load and with direct current Permissible medium Operating temperature range Weight Circuit closer Circuit breaker bar max. set at 0. ± 0. bar 5.0 ± 0. bar adjustable from 0. to. bar.0 to 5.0 bar M x deep IP 6 0 V max. A max. Air - 0 C to + 80 C 0. kg Installation: Adjusting screw 55

56 . 0 Pressure Switch Technical Data: Switching pressure bar Range of adjustment bar Switching pressure Part Number Operating pressure Breaking pressure Type of protection in accordance with DIN Operating voltage 5 bar max..8 bar. bar IP 55 Electrical breaking capacity 8 A max. (ohmic load) 7 A max. (inductive load: L/R ms) Thread of pipe connections G / ISO 8 Permissible medium Operating temperature range Weight DC Air, Oil - 5 C to + 70 C 0.6 kg P P Installation instructions supplied with the device. + opening or closing + Installation: ø, angle included in switch package 5,5 ø 5, 9 60 Space required for switch setting 70 ø 5, ø 6 0 ø 5,,5 N 6 09 PG,5,5, SW 7 56

57 Accessories for Hose Couplings Fastening clamp Part Number For hose couplings 5 00 / 5 0 In accordance with Standard Weight C DIN kg Dummy coupling with chain Part Number For hose couplings In accordance with Standard Weight VDA 7 0. kg Dummy coupling with fastening Part Number For hose couplings 5 00 / In accordance with Standard Weight VDA 7 0. kg 57

58 Shut-off cock with Exhaust Purpose: To shut off an air line and vent the down stream line. Operation: When the lever (a) is parallel to the longitudinal axis of the stop cock the eccentric shaft (c) pushes valve (d) to the left against the spring (e). Air passes unrestricted from port through the inlet (f) to the line leading from port. If the lever (a) is turned through 90 degrees to its stop, the spring (e) moves valve (d) to the right and the inlet (f) is closed. The line leading from port is vented through the exhaust drilling (b). Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The stop cock may be installed at any angle using the two mounting holes. Technical Data: Part Number Operating pressure 0 bar max. Thread of pipe connections M x.5 - deep lever actuation a / b 90 Permissible medium Air Operating temperature range - 0 C to + 80 C Weight 0.5 kg Installation: Port connections: = Energy supply = Energy delivery 58

59 Duo-Matic Quick Coupling for Trailers Purpose: To connect the compressed air braking system of the motor vehicle to that of the trailer. Operation: When attaching the trailer, handle (b) is pushed downwards; this causes protective caps (a) and (d) to open. The Duo-Matic trailer portion is placed below the protective caps and handle (b) is released. Torsion spring (e) acts upon protective caps (a) and (d), pushing the trailer portion against the automatic closing valves (c), causing them to open: Compressed air now reaches the trailer. Maintenance: No special maintenance is necessary beyond the legal requirements. When attaching the trailer, make sure that all contact surfaces are clean. In the event of any leakage, change the valves or junk rings. Installation Requirements: The Duo-Matic Quick Coupling is to be installed as per DIN 78 standard. Installation schematic: 59

60 Duo-Matic Quick Coupling for Trailers Technical Data: Part Number Operating pressure Nominal diameter Permissible medium Operating temperature range Hose connection piece Tractor portion Ø 0 mm Ø mm 0 bar max. 9 mm Air - 0 C to + 80 C Trailer portion Sealing ring M6 x Weight.0 kg 0. kg Installation: Tractor portion Port connections: = Energy supply = Service Trailer portion 60

61 Duo-Matic Quick Coupling for Semi-trailers Purpose: To connect the compressed air braking system of the semi-trailer tractor to that of the semi-trailer. Operation: When attaching the semi-trailer, handle (b) is pushed downwards; this causes protective caps (a) and (d) to open. The Duo-Matic tractor portion is placed below the protective caps and handle (b) is released. Torsion spring (e) acts upon protective caps (a) and (d), pushing the tractor portion against the contact surface. The automatic shut-off valves (c) open and compressed air reaches the semi-trailer. Maintenance: No special maintenance is necessary beyond the legal requirements. When attaching the semi-trailer, make sure that all contact surfaces are clean. In the event of any leakage, change the valves or junk rings. Installation Requirements: The Duo-Matic Quick Coupling is to be installed as per DIN 78 standard. Installation schematic: 6

62 Duo-Matic Quick Coupling for Semi-trailers Technical Data: Part Number Operating pressure Nominal diameter Permissible medium Operating temperature range Hose connection piece Semi-trailer portion Ø 0 mm Ø mm 0 bar max. 9 mm Air - 0 C to + 80 C Tractor portion Sealing ring M6 x Weight.0 kg 0. kg Installation: Semi-trailer portion Port connections: = Energy supply = Service Tractor portion 6

63 Raise/Lower Valve 6 0. Fig I II III IV V STOP STOP Purose: Control of raising / lowering of air suspended interchangeable platforms and semitrailer chassis (lifting device). The rotary slide valve includes the deadman control meeting the accident prevention requirement of the metal professional association (German VBG 8, 8). An automatic return is required for chassis movement with a stroke more than 00 mm, measured at the axle. With these valves, the lever automatically returns to raise/stop respectively lower/stop, all other functions are like described below. Operation: When the lever is in the driving position, the lifting device is switched off. The rotary slide valve has an open passage between the levelling valves (port to ) and the bellows (ports and ) Upon that, this device enables further lever park positions allowing pressurizing/ venting of the bellows for raise/ lower function. To raise the chassis, the lever is dislocked with pressing it down axially and then turned across position stop to position raise. This will close ports ( and ) and connect the bellows ( and ) with reservoir at port. After reaching the desired height, the hand lever is to be turned to stop position. In this position, all ports to the levelling valve ( and ) aswell as those to the bellows ( and ) are closed. Support arms can now be turned out. The afterwards required lowering of the chassis under normal level and place down a container or the loading platform and to drive out is done with the hand lever position lower. Like in the position raise, the ports ( and ) are now closed. However, the bellows ( and ) are vented over exhaust. This procedure is also stopped via turning back to the stop position. The ports,, and are closed. After driving out of the chassis the hand lever is to switched to driving position to switch back to level control with levelling valves. Maintenance: No maintenance is necessary beyond the tests required by law. Installation Requirements: Using four bolts M8, the Raise/Lower Valve is to be installed either vertically - port () pointing downwards - or horizontally. The plate supplied showing the lever positions is to be affixed below the handle (please also refer to the section on Installation ). 6

64 . 6 0 Raise/Lower Valve Technical Data: Part Number Operating pressure Nominal diameter Thread of pipe connections 0 bar max., =.6 mm ( Ø mm), = 8. mm (Ø 6 mm), = 6.6 mm (Ø 9 mm) M x.5 - deep = M6 x.5 - deep Type single circuit =.6 mm = 8. mm, = 6.6 mm M x,5 - deep Check valve (port ) with without with Permissible medium Operating temperature range Operating torque Weight Air - 0 C to + 80 C 7 Nm max.. kg Part Number Operating pressure Nominal diameter Thread of pipe connections Permissible medium Operating temperature range Operating torque Weight 8,5 bar max., =.6 mm ( Ø mm), = 8. mm (Ø 6 mm), = 6.6 mm (Ø 9 mm) M x.5 - deep = M6 x.5 - deep Air - 0 C to + 80 C 9 Nm max..5 kg Position I Raise II Stop III Travelling IV Stop V Lower Port closed closed interconnected closed closed Port pressurized closed closed exhausted Port closed closed interconnected closed closed Port pressurized closed closed exhausted 6

65 Raise/Lower Valve 6 0. Installation: Valve shown locked: By depressing the knob, the valve is unlocked. View X shown: Port connections: = Levelling valve = Suspension bellows = Levelling valve = Suspension bellows = Reservoir = Exhaust Stroke for park position Stroke for park position Fig. 0 0 Fig

66 . 6 0 Release Valve Purpose: Exhausting the front wheel brake actuators when the trailer is uncoupled. Operation: To release the front wheel brake actuators, piston (b) is pushed fully home via actuator button (a), thus blocking the passage from port to port. The compressed air at port is exhausted to atmosphere via port - and via the hose coupling of the supply line. If piston (b) has not yet been pulled out manually when the trailer is again coupled to the motor vehicle, the supply pressure coming from the motor vehicle via port - will do this automatically. The release valve is again in its driving position in which ports and are connected. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The release valve can be mounted directly on the flange of the trailer brake valve, using two screws M8, or in the pipe upstream from the adapter valve. Technical Data: Part Number Operating pressure 0 bar max. Flange seal Part Number Operating torque Port ; 55 Nm max. Port - 50 Nm max. Permissible medium Air Operating temperature range - 0 C to + 80 C Weight 0. kg Installation: Port connections: = Energy supply = Energy delivery - = Exhaust or pilot connection Threads of pipe connections:, = M x.5 - = M6 x.5 66

67 / Directional Control Valve Purpose: Alternate connection of the service line (consumer) with the pressure line or the exhaust, the valve locking into either position. Operation: When turning knob (a) is actuated in a rotary direction, piston (b) is moved downwards via a cam. Outlet (d) closes and inlet (c) opens, and the compressed air at Port flows into the service line via Port. When turning knob (a) is turned the other way, piston (b) is returned to its original position by the force of the compression spring. Inlet (c) closes and the service line is exhausted via outlet (b) and Port. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: The / directional control valve is fitted in the pipe system with Outlet pointing downward. It is fastened on a console (bore Ø 6) using counter nut M8 x.5. Technical Data: Part Number Operating pressure Thread of pipe connections Nominal diameter Permissible medium Operating temperature range Weight 0 bar max. M6 x.5 - deep for VOSS plug connection mm Air - 0 C to + 80 C 0.5 kg Installation: Port connections: = Energy supply = Energy delivery = Exhaust pressurizing process commences 67

68 Lift Axle Control Valve 0 0 II II I I Fig. 000 Fig. 00 Purpose: The lift axle control valve is used to manually or automatically raise or to automatically drop the lift axle(s) once the axle(s) which is (are) in contact with the ground have reached their permissible load. Variants for mechanical actuation for electrical actuation fully automatic, pneumatic actuation Operation: For dropping the lift axle, compressed air from port (air suspension bellows) flows via duct (k) through the throttle of the check valve (d) to port (balance reservoir) and through duct (f) into Chamber B. Once the actuating pressure set by means of screw (c) has been reached, piston (e) is raised. The compressed air now flows via duct (g) into Chamber A, moving tappet (b) into its upper end position. Port (supply) is closed. Port 0 and Chambers D and E are connected via Outlet. Tappets (h and i) move to their lower stop positions and a connection is established between the ports for the air suspension bellows ( and ). To raise the lift axle, the actuating knob (a) is pushed in (possible only if piston (e) is lowered) and the air supply flows via port 0 to the downstream lifting bellows. At the same time, compressed air flows via duct (j) into Chambers D and E, forcing tappets (h and i) upwards against the compression springs. The connection of the ports for the air suspension bellows ( and ) as well as ( and ) is closed and the compressed air from the lift axle's air suspension bellows (ports and ) is released to atmosphere after flowing via tappets (h and j), Chamber C and Exhaust. Funktion of port refer to page 75. Maintenance: No special maintenance is necessary beyond the legal requirements. Installation Requirements: This valve can be fastened using stud bolts M6 [A] (tightening torque 0 Nm) or screws M8 [B], tightening torque 0 Nm (through holes 9 mm are provided on the valve). The fitting position for the lifting axle control valve is shown on page II I Fig

69 Lift Axle Control Valve Technical Data: Part Number Operating pressure bar max. Actuation mechanical electrical pneumatic Nominal diameter Permissible medium Operating temperature range 7 mm Air - 0 C to + 80 C Pressure adjustment lowering.5 to 7 bar.5 to 7 bar Preset operating pressure ± 0, bar lowering.5 ± 0. bar lifting.5 ± 0. bar Adjustable hysteresis.5 to bar Voltage volts + 6 V -. V Operating voltage DC Rated current I N = 0. A Weight. kg Installation: 6,5 9 9 shown: Port connections: = Energy supply 0 = Lift bellows, = Suspensions bellows vehicle, = Suspensions bellows lift axle = Exhaust = Damping volume = Test point to set switching pressure(s) 5 ø 9 ø , 97, M 6 Threads of pipe connections:,,,,, = M 6 x.5 0 = M x.5 = M 6 x.5 (ISO 58) lifting HEBEN lowering SENKEN ø , ,5 69

70 Lift Axle Control Valve Installation: 5,5,7 6, ø M 7x 6, ø 9 ø , 97, 8,5 0, 97, 5, M ø 9 ø B B B B A A ø A SW M 6 A 57, ,5 57, ,5 shown: shown: Installation position: Optional only 70

71 Lift Axle Control Valve Setting Instructions: Enclosed size Range of adjustment Width across flats0 M = ± Nm Width across flats M = 5 Nm max. M =.5 Nm max. After having correctly installed the valve, according to instructions, the switching pressure(s) must be set mechanically operated version (circuit diagram see Page ) Push in the operating knob. The switching pressure to lower the lift axle must be set to a pressure which ensures that the admissible axle load is not exceeded. To do so, a test hose, with pressure gauge and pressure reduction valve, must be connected to port. Increase the pressure at the test port to determine the switching pressure at which the operating button comes out, exhausting the lift bellows and pressurising the lift axle bellows (lift axle drops). If the switching pressure is too high, it can be reduced by screwing out the setting screw. If too low, it can be increased by screwing in the setting screw. lowering lifting stop = 5 turns > The switching pressure for automatic drop must always be checked using rising pressure (to avoid incorrect setting due to hysteresis). Once adjustment is complete tighten the lock nut on the adjusting screw and cover with the cap provided electrically operated version (circuit diagram see Page ) Pressure switch (setting range.0 to 5.0 bar) must be installed according to the circuit diagram. The pressure switch setting method is similar to that used to set the mechanically operated version fully automatic pneumatic version (circuit diagram see Page ) Two switching pressures must be set. First remove the protection cap (SW0; M = 5 ± 5 Nm), then using a cross slotted screw driver (size ) adjust the setting screw (A) downwards until it reaches its stop. The switching pressure for automatic lowering can now be set. Using a mm allen key adjust setting screw (B) using the method previously described for the mechanical version. Once the lowering pressure has been set the switching pressure for automatic lifting can be set by adjusting screw (A). The lifting pressure must always be set using falling pressure. Replace protection cap. The difference between the lifting and lowering switching pressures must be at least 0. bar higher than the increase in the bellows pressure on the non-lifting axle(s) when an axle is lifted. 7

72 Damping reservoir Damping reservoir for lifting axle control valve: To prevent from unintentional lowering of the lifting axle, a damping volume is required. the damping reservoir is a low cost solution since it is directly fitted to port of lifting axle control valve Technical Data: Part Number Volume dm Ambient temperature: Operating pressure max.: Operating torque Material Colour - 0 C to + 60 C p e = 8.5 bar at 60 C p e = 0 bar at 0 C 6 + Nm Plastic black male stud thread M 6 x.5 Installation position optional Installation: 7

73 Lifting Axle Control Valve Purpose: The range of the conventional liftingaxle valve has been expanded with a one circuit variant. This means a lifting axle can be automatically controlled as traction help by the trailer EBS D depending on the current axle load. Electrical control and monitoring is performed by the trailer modulator. Operation: The supply line, coming from reservoir is connected to port. The armature (d) which forms the valve core keeps inlet (c) closed and the lifting bag port is connected to exhaust. When a current reaches solenoid coil, armature (d) is lifted, and inlet (c) is opened. The supply air moves the piston (a) down against the force of spring (b). The connection of the bellows ( with ) is closed and compressed air from the bellows of the lifting axle (port ) is venting through piston (a) and exhaust to atmosphere. In parallel, supply air pressurises from port via port the downstream lifting bag. To lower the lifting axle, the current to the solenoid coil is interrupted and armature (d) closes inlet (c). The compressed air upon piston (a) is venting via solenoid coil and exhaust. The pressure spring lifts piston (a) and the lifting axle control valve is ist inital position where ports ( with ) and ( with ) are connected. A traction help with residual pressure holding is possible after unscrewing the vent. To do this, a line is routed from the vent to the /-way solenoid valve for residual pressure holding and port IN/OUT of the modulator must be connected via cable The lifting axle valve vent (connection ) is shut off by a -way valve, vented accordingly by the EBS D modulator and the maximum possible bellows pressure is retained. The traction help can be activated by a button. (Diagram see page ) Technical Data: Part Number Operating pressure Nominal diameter Permissible medium Operating temperature range Voltage bar max. Ø 8 mm Air - 0 C to + 80 C volts + 6 V -. V Operating voltage Rated current Type of protection in accordance with DIN 0050 Weight DC I N = 0. A IP 6K9K.5 kg 7

74 Lifting Axle Control Valve Installation: Port connections: = Energy supply = Port lifting bag = bellows vehicle = bellows lifting axle, = Exhaust Threads of pipe connections:,,, = M 6 x.5 connecting cable EBS Modulator: Part Number Length L (mm) Length L (mm)