PNEUMATIC BRAKE EQUIPMENT FOR TRAILER VEHICLES

PRODUCT CATALOGUE

PNEUMATIC BRAKE EQUIPMENT FOR TRAILER VEHICLES

Table of contents

3

Table of contents

Table of contents1 General information ......................................................................................................................................... 5

2 Safety information .......................................................................................................................................... 10

3 Introduction .................................................................................................................................................... 12

4 Schematic diagram ........................................................................................................................................ 134.1 Lift axle circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.2 Air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 Device description ......................................................................................................................................... 195.1 Diaphragm cylinder 423 XXX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2 Linefilter432500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.3 Ventvalve43270X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305.4 Knucklejoint433306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5 Linkage433401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.6 Checkvalve434014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.7 Chargingvalve434100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.8 Two-WayValve434208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.9 Pressureswitch441009/441014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.9.1 Pressure switch 441 009 ......................................................................................................... 415.9.2 Pressure switch 441 014 ......................................................................................................... 43

5.10 Pressuresensor441044. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.11 Shut-offcockwithventing452002/952002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465.12 Dummycouplingwithfastening452402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.13 Duo-Maticquick-coupling45280X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.14 Rotaryslidevalve463032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545.15 3/2directionalcontrolvalve463036 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575.16 Liftingaxlecontrolvalve463084 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.16.1 2-circuit lifting axle control valve 463 084 0XX 0 ..................................................................... 595.16.1.1 Mechanically actuated lifting axle control valve 463 084 000 0 ............................. 635.16.1.2 Electrically actuated lifting axle control valve 463 084 010 0 ................................. 635.16.1.3 Fully automatic pneumatic lifting axle control valve 463 084 020 0 ....................... 63

5.16.2 Single circuit lifting axle compact valve (spring-returned) 463 084 031 0 ............................... 645.16.3 Two-circuit lifting axle control valve (pulse-controlled) 463 084 100 0 .................................... 66

5.17 TASC–Return-to-Ridevalve463090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685.18 Dampingreservoir4630840202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725.19 Testconnection463703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.20 Levellingvalve464006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.21 Plug-incouplingsforlevellingvalves893000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.22 3/2directionalcontrolvalve4721XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825.23 Pressurereductionvalve473301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .865.24 Quickreleasevalve473501/973500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 885.25 Pressurelimitingvalve475010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925.26 Loadsensingvalve(LSV)47571X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.26.1 LSV 475 712............................................................................................................................ 945.26.2 LSV 475 713............................................................................................................................ 995.26.3 LSV 475 714.......................................................................................................................... 1045.26.4 LSV trailer brake valve 475 715 .............................................................................................1115.26.5 Plates "Set values LSV " 899 144 63X 4 ............................................................................... 119

5.27 Load-dependentcontrolvalve475800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1215.28 Tristop®Cylinder925XXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4

Table of contents General information

5.29 Drainvalve934300/934301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1335.30 Airreservoir950XXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1365.31 Couplinghead95220X/452XXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

5.31.1 Coupling head 952 20X ......................................................................................................... 1395.31.2 Couplingheadwithintegratedlinefilters952201................................................................. 143

5.32 Doublereleasevalve963001/Trailerreleasevalve963006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1455.33 Shut-offvalve964001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1505.34 Trailerbrakevalvewithadjustablepredominance971002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.34.1 Trailer brake valve 971 002 152 0 ......................................................................................... 1605.35 Parkreleaseemergencyvalve(PREV)971002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1635.36 Relayvalve9730XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

5.36.1 Overload protection valve 973 011 201 0 .............................................................................. 1695.37 Proportioningpressureregulator975001/975002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5.37.1 Proportioning pressure regulator with straight characteristic curve 975 001......................... 1725.37.2 Proportioning pressure regulator with drop characteristic curve 975 002 ............................. 176

Edition 4 This publication is not subject to an updating service. Youwillfindthecurrentversionat: http://www.wabco.info/i/1021

http://www.wabco.info/i/8150100343

5

General information

1 General informationSymbols used in this document

ii

Importantinformation,notesand/ortips

www www

@

@ @@

Reference to information on the internet

– Action step

Ö Consequenceofanaction

� List

• List

WABCO Academywww www

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https://www.wabco-academy.com/home/

WABCO Online product cataloguewww www

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http://inform.wabco-auto.com/

6

General information General information

Your direct contact to WABCO

WABCOBelgiumBVBA

‘tHofveld6B1-3

1702Groot-Bijgaarden

Belgium

T:+3224810900

WABCOGmbH

Am Lindener Hafen 21

30453Hanover

Germany

T:+495119220

WABCOAustriaGesmbH

Rappachgasse 42

1110Vienna

Austria

T:+431680700

WABCO(Schweiz)GmbH

Freiburgstrasse 384

3018Bern

Switzerland

T:+41319974141

WABCOAutomotiveBV

Rhijnspoor263

CapelleaandenIJssel(Rotterdam)2901LB

Netherlands

T:+31102888600

WABCObrzdykvozidlůmspol. s r.o.

Pražákova1008/69,Štýřice,

63900Brno

CzechRepublic

T:+420602158365

WABCOFrance

CARREHAUSMANN

1coursdelaGondoire

77600Jossigny

France

T:0801802227

WABCOAutomotiveItaliaS.r.L.

CorsoPastrengo50

10093Colegno/Torino/

Italy

T:+390114010411

WABCOTechnicalOffice,SalesOffice&TrainingCentre

Siedlecka 3

93138Łódź

Poland

T:+4842680914

WABCOEspañaS.L.U.

AvdeCastilla33

San Fernando de Henares

Madrid28830

Spain

T:+34916751100

WABCOAutomotiveAB

Drakegatan10,Box188SE40123Gothenburg

Sweden

T:+4631578800

WABCOAutomotiveU.K.Ltd

UnitA1GrangeValley

GrangeValleyRoad,Batley,W Yorkshire,

А́нглия,WF176GH

T:+44(0)1924595400

Head office: WABCOEuropeBVBA,ChausséedelaHulpe166,1170Brussels,Belgium,T:+3226639800

7

General information

Before choosing the right trailer system, a few general points must be considered:

WABCO recommends a brake calculation for every type of trailer braking system.

The braking systems in this document do not take the special conditions of the trailer such as trailer dimensions, axle types, wheel brake type, tyre type, etc. into account. Based on the brake calculations, it may be possible to determine whether the braking system is suitable for the applications involved.

Foracorrectbrakecalculation,itisimportantthatthe"Technicalvehicledata"applicationformisfilledout. The application form can be located at the end of this chapter.

MoreinformationandsupportcanbeobtainedthroughyourWABCOpartner.

Trailer braking system with automatic load-dependent brake force controller (LSV) must be set up before the installation.

TheLSVsintrailersareuniversalvalves."Universal"doesnotmeanPlug&Play,itmeansthattheLSVcanbeusedfordifferenttypesoftrailers.

TheLSVmustbesetbeforeinstallationinthebrakingsystem,seechapter5.26"Loadsensingvalve(LSV)47571X",page94,page110(Tools,Parameterdefinition,Setting,LSVdataplate)anddocumentation"LSVtestequipment4350080000",seechapter3"Introduction",page12.

The setting parameters must be calculated.

ThereareseveralwaystodeterminetheparametersfortheLSVsetting,forexample:

� Calculationwith"nomographs"

� Calculationwith"LSVcalculationsoftware"

� Calculationwith"Trailerbrakecalculation"-thisservicecanberequestedfromWABCO

Inordertodothis,WABCOrequiresacompletedapplicationformforthebrakecalculation,whichyoucanfindattheendofthechapter.

In accordance with legal requirements, the vehicle must be marked with the required information regardingtheLSVtesting.TherespectivesignscanbeobtainedthroughWABCOforthis,seechapter5.26"Loadsensingvalve(LSV)47571X",page94.


In the air suspension system of the trailer there is a levelling valve which must be adjusted.

Thelevellingvalve4640061000intheairsuspensionsystemhasalever.Theoptimalsuspensionconditionsaredefinedwiththeleverlength.Theheightlimitationcanalsobedefined,seechapter5.20"Levellingvalve464006",page75.


The lift control valve may have to be set before the installation for air suspension systems on trailers with lifting axle control valve 463 084 000 0.

Theliftingaxlecontrolvalve(LACV)intrailersisauniversalvalve.Itcanbeusedforvariousliftingaxlecontrolrequirements.TheliftingaxleisloweredmanuallywiththeLACV.Theliftingaxleisraisedautomatically.TheLACVisfactory-setsothatitraisestheaxlewithabellowspressureofapproximately4bar(switchingpoint).

Ifitisnecessarytolifttheliftingaxleatadifferentswitchingpoint,thiscanbeadjusted,seechapter5.16"Liftingaxlecontrolvalve463084",page59.

8

General information General information

WABCOTechnical vehicle data

for the brake calculation for trailers

VehicleManufacturer: Type:Vehicle acceptance according to: EC/ECE other max. speed

Country of initial registration

Central axle trailer Name laden unladen

PSt PSt

P1 P1 P2

PSt

P1 P2 P3

Total mass P kg

Noseweight PNw kg

Axle load axle 1 P1 kg



Drawbar trailer laden unladen

P1 P2

ER

h

P1 P2

ER

h

P3

Total mass P kg




Centreofgravityheight h mm

existing wheelbase ER mm

Wheelbase range ER mm

Semitrailer laden unladen

P1

ER

h

P1

ER

h

P2

P1

ER

h

P2 P3

Total massmin. P kg

max P kg




Centreofgravityheight h mm

existing wheelbase ER mm

Wheelbase range ER mm

r Bn

r dyn

r Bt

L BH

Axle 1 2 3

Cylinder:Number/Type KDZ

possible lever lengths IBH mm

Drum/discradius rBt mm

C°

mech.efficiency η %

Camradius rBn mm

dyn. unloaded tire diameter or tireidentification

min.

rdyn mmexisting

max

Threshold torque MAL Nm

Axle manufacturer: Type: Test report number:Brake size: For "standard axles" only axle manufacturer and test report number required!

WABCO circuit diagram no.: Axle assemblies see back side!

Trailing steering axle: Tristop cylinder: ABS VCS: EBS:

9

General information

WABCOTechnical vehicle data

for the brake calculation for trailers

Multi-axle assemblies Manufacturer: Type:Air suspension Springlinkl1/l2(mm): /

or Springlinkx1/x2(mm): /

Bellowsdiameter(mm):

Drawingno.:

Leaf spring multi-axle assembly (with dyn. compensation)

Leaf spring multi-axle assembly (without dyn. compensation)

Balance beam multi-axle assembly Individual axles mechanical

Please enclose drawing if assembly is not listed here!

Bellowspressure(bar) laden unladen Springdeflection(mm)

Frontaxle: Frontaxle:

Rearaxle(s): Rearaxle(s):

Semitrailer with lifting axle(s)

l1 l1

1 2 3

Axle 1 2 3

Whichaxle(s)aretobelifted(x):

Axledistancel1(mm):

Bellowspressureladen(bar):

Bellowspressureunladen(withaxle/slifted)(bar):

Bellowspressureunladen(allaxleslowered)(bar):

Axleload(s)unladen(withaxle(s)lifted)(kg):

Axleload(s)unladen(allaxleslowered)(kg):

10

Safety information Safety information

2 Safety informationObserve all necessary regulations and instructions:

� Read this document carefully. Adhere to all instructions, information and safety information to prevent injury to persons and damage to property. WABCOwillonlyguaranteethesafety,reliabilityandperformanceoftheirproductsandsystems if all the information in this publication is adhered to.

� Alwaysabidebythevehiclemanufacturer'sspecificationsandinstructions.

� Observeallaccidentregulationsoftherespectivecompanyaswellasregionalandnationalregulations.

Make provisions for a safe work environment:

� Onlytrainedandqualifiedtechniciansmaycarryoutworkonthevehicle.

� Usepersonalprotectiveequipmentifrequired(safetygoggles,respiratoryprotection,earprotectors,etc.).

� Pedal actuations can lead to severe injuries if persons are in the vicinity of the vehicle. Make sure thatpedalscannotbeactuatedasfollows:

• Switch the transmission to "neutral" and actuate the park brake.

• Secure the vehicle against rolling with chocks.

• Fasten a visible note to the steering wheel indicating that work is being performed on the vehicle and that the pedals are not to be actuated.

Avoiding electrostatic charge and uncontrolled discharging (ESD)

Note during construction and building the vehicle:

� Preventpotentialdifferencesbetweencomponents(e.g.axles)andthevehicleframe(chassis). Make sure that the resistance between metallic parts of the components and the vehicle frame is lessthan10Ohm(<10Ohm). Establishanelectricallyconductiveconnectionbetweenmovingorinsulatedvehicleparts,suchas axles, and the frame.

� Preventpotentialdifferencesbetweenthetowingvehicleandthetrailer.

� Make sure that an electrically conductive connection is made between metal parts in the towing vehicleandthecoupledtrailerviathecoupling(kingpin,fifthwheel,clawswithpins),evenwithouta cable being connected.

� UseelectricallyconductiveboltedconnectionswhenfasteningtheECUstothevehicleframe.

� UseonlycableconformingtoWABCOspecificationsororiginalWABCOcable.

� Runthecablewithinmetalliccasingswherepossible(e.g.insidetheU-beam)orbehindmetalandgroundedprotectiveplatingtominimisetheinfluenceofelectro-magneticfields.

� Avoid the use of plastic materials if they can cause electrostatic charging.

11

Safety information

While carrying out repair or welding work on the vehicle, observe the following:

� Disconnectthebattery(ifinstalledinthevehicle).

� Disconnect cable connections to devices and components and protect connectors and ports against contamination.

� Always connect the grounding electrode directly with the metal next to the welding point when weldingtopreventmagneticfieldsandcurrentflowviathecableorcomponents. Make sure that current is well conducted by removing paint or rust.

� Preventheatinfluencesondevicesandcablingwhenwelding.

12

Introduction

Schematic diagramLift axle circuits

3 IntroductionThe equipment for towing vehicles is subject to continual changes, which are either caused by improving technology or more legal requirements.

Spring chamber cylinders have become mandatory in towing vehicles and will secure a parked trailer or even the entire train from rolling in case of a complete pressure-loss in the braking system. An additional mechanical parking brake with cables is not required.

Disc brakes are becoming ever more popular in wheel brakes. In comparison with drum brakes, they are easier to maintain and are not as subject to fading, diminishing braking performance over long downgrades.

ABS is required legally in most regions and is an equipment standard now.

TrailerEBSisanotheradditiontotrafficsafety.Brakingisshortenedbytheelectronictransferofthebraking request. ABS and the RSS safety system are integrated. Additional devices for adapting the braking pressure to the load status are not required.

Air suspension is implemented in almost all utility vehicles nowadays. Not only the cargo but the streets too are preserved. In addition, a constant ride height and the adjustability to various ramp heights also speak for the air suspension.

RampheightscanbelearnedandmovedtowiththepushofabuttonwithtrailerECAS.Inaddition, a multitude of lifting axle circuits and special functions are possible.

WiththeTrailerEBSE,thecomplexityofthetrailercontrolisincreasedagain.ThisdeviceincludesthecompletebrakingsystemwithanECASsystem.Thecontrolofothercomponentsofthetowingvehiclecan also be handled.

13


4 Schematic diagramwww www

@

@ @@

– OpentheWABCOINFORMonlineproductcatalogue: http://inform.wabco-auto.com

– Search for documents by entering the diagram number.

4.1 Lift axle circuits

Number

Sing

le c

ircui

t

Dua

l circ

uit

Elec

tr.

actu

ated

Mec

han.

ac

tuat

ed

Fully

au

tom

atic

co

ntro

l

Trac

tion

help

(T

H)

Low

erin

g fu

nctio

n

Rot

ary

slid

e va

lve

TASC

Hei

ght l

imiti

ng

leve

lling

val

ve

2 LA

CV

ELM

Res

idua

l pr

essu

re

rem

arks

ABS

8418014470 x x

8418014480 x x

8418014490 x x

8418014720 x x x

8418014730 x x x

8418014760 x x x 2LACV

8418014790 x x x

8418015200 x x x

8418015220 x x x

8418015240 x x x x x 5-axletrailer,2LACV

8418015250 x x x StVZO§41

8418015290 x x x x

8418015720 x x x

8418015730 x x x x x x

8418015740 x x x x x

8418015760 x x x x 2LACV

8418016000 x x

8418019270 x x x x x

8418019280 x

EBS8418017910 x x x x withELM

8418017920 x x x x withELM

8418019200 x x x x x x

8418019210 x x x x x x x xSwitch for lifting axle

controller in trailer


controller in towing vehicle



8418019240 x x x x x x



14


Schematic diagramAir suspension

Number

Sing

le c

ircui

t

Dua

l circ

uit

Elec

tr.

actu

ated

Mec

han.

ac

tuat

ed

Fully

au

tom

atic

co

ntro

l

Trac

tion

help

(T

H)

Low

erin

g fu

nctio

n

Rot

ary

slid

e va

lve

TASC

Hei

ght l

imiti

ng

leve

lling

val

ve

2 LA

CV

ELM

Res

idua

l pr

essu

re

rem

arks



8418019290 x x x x x x x x xSwitch for lifting axle




8418020710 x x x x x x xSwitch for lifting axle

controller in trailer and towing vehicle








controller in trailer

8418020760 x x x x x xSwitch for lifting axle








8418021380 x x x x x x x x with2single-circuitLACV

15


4.2 Air suspension

Axles In connection with braking system

Number Height sensor

Lifting axle(s)

Comment ECAS ECU

Semitrailer1-2-3 axle

VCS 8418017220 1 1 4460550650

2-3 axle VCS 8418017230 1 1 4460550650

2-3 axle VCS 8418017240 2right/left

1 4460550650

2-3 axle VCS 8418017250 2 1 4460550650

3 axles VCS 8418017260 1 2 separate

4460550650

2-3 axle VCS 8418017270 1 1Trailing-AxleControl 4460550650

2-3 axle VCS 8418017300 1 1 Train transport 4460550650

2-3 axle VCS 8418017310 1 Traction help 4460550650

1-3 axle VCS 8418017320 1 Tiredeflectioncompensation 4460550650


4460550650

3 axles VCS 8418017340 2right/left

2 4460550650

2-3 axle VCS 8418017350 2 4460550650


4460550650

2-3 axle VCS 8418017370 2right/left

4460550650

3 axles VCS 8418017800 1 2 parallel 4460550650

2-3 axle VCS 8418017820 2 Tiredeflectioncompensation 4460550650

1-2-3 axle

VCSII 8418020220 1 4460550650

2-3 axle VCSII 8418020230(intheannex)

1 1 4460550660

2-3 axle VCSII 8418020240 2right/left

1 4460550660

2-3 axle VCSII 8418020250 2 1 4460550660

3 axles VCSII 8418020260 1 2 separate

4460550660

2-3 axle VCSII 8418020270 1 1Trailing-AxleControl 4460550660

2-3 axle VCSII 8418020800 1 1 Train transport 4460550660

2-3 axle VCSII 8418020810 1 Traction help 4460550660

1-3 axle VCSII 8418020820 1 Tiredeflectioncompensation 4460550660


4460550660

3 axles VCSII 8418020840 2right/left

2 4460550660

2-3 axle VCSII 8418020850 2 4460550660


4460550660

16





Lifting axle(s)

Comment ECAS ECU

2-3 axle VCSII 8418020870 2right/left

4460550660

3 axles VCSII 8418020890 1 2 parallel 4460550660

2-3 axle VCSII 8418020910 2 Tiredeflectioncompensation 4460550660

2-3-4 axle

EBS 8418017500(intheannex)

2 with front axle valve 4460550660

2-3-4 axle

EBS 8418017510 2 without front axle valve 4460550660

1-2-3 axle

EBS 8418017520 1 4460550660

2-3 axle EBS 8418017530(intheannex)

1 1 4460550660

2-3 axle EBS 8418017540 2right/left

1 4460550660

2-3 axle EBS 8418017550 2 1 4460550660

3 axles EBS 8418017560 1 2 separate

4460550660

2-3 axle EBS 8418017570 1 1Trailing-AxleControl 4460550660

2-3 axle EBS 8418017600 1 1 Train transport 4460550660

2-3 axle EBS 8418017610 1 Traction help 4460550660

1-3 axle EBS 8418017620 1 Tiredeflectioncompensation 4460550660


4460550660

3 axles EBS 8418017640 2right/left

2 4460550660

2-3 axle EBS 8418017650 2 4460550660


4460550660

2-3 axle EBS 8418017670 2right/left

4460550660

3 axles EBS 8418017690 1 2 parallel 4460550660

2-3 axle EBS 8418018210 2 Tiredeflectioncompensation 4460550660

3 axles EBS 8418018220 1 1staxle:Tractionhelp3rdaxle:Manoeuvringassistance

4460550660


2ndliftingaxle:Manoeuvringassistance+Forcedlowering

4460550660

3 axles EBS 8418018240 1 1 single circuit 4460550660

3 axles EBS 8418018250 1 2 single circuit 4460550660


4460550660

3 axles EBS 8418018270 1 1 without traction help 4460550660

2-3 axle EBSE 8418021500(intheannex)

1 ConventionalairsuspensionLevelling valve

3 axles EBSE 8418020170 1 Battery operation 4460550660

17




Lifting axle(s)

Comment ECAS ECU

Drawbar trailer2 axles with/without

ABS/EBS8418014340(intheannex)

Levelling valve

3 axles with/withoutABS/EBS

8418014350(intheannex)

Levelling valve with height limitation and rotary slide valve

1-3 axle with/withoutABS/EBS


Levelling valve

1-3 axle with/withoutABS/EBS


Levelling valve with height limitation and rotary slide valve

2-3-4 axle

VCS 8418017200 2 with front axle valve 4460550650

2-3-4 axle

VCS 8418017210 2 without valve throttle 4460550650

3-4 axle VCS 8418017280 3 with front axle valve 4460550650

3-4 axle VCS 8418017290 3 1 with front axle valve 4460550650

3-4 axle VCS 8418017380 2 1 with front axle valve 4460550650

2-3 axle VCS 8418017810 2 with front axle valve, Train transport

4460550650

2-3-4 axle

VCSII 8418020200(intheannex)

2 with front axle valve 4460550660

2-3-4 axle

VCSII 8418020210 2 without valve throttle 4460550660

2-3-4 axle

VCSII 8418020280 3 with front axle valve 4460550660

3-4 axle VCSII 8418020290 3 1 with front axle valve 4460550660

3-4 axle VCSII 8418020880 2 1 with front axle valve 4460550660

2-3 axle VCSII 8418020900 2 with front axle valve, Train transport

4460550660

2-3 axle VCSII 8418020920 2 2x rear axle valve 4460550660

2-3-4 axle

EBS 8418017580 3 with front axle valve 4460550660

3-4 axle EBS 8418017590 3 1 with front axle valve 4460550660

3-4 axle EBS 8418017680 2 1 with front axle valve 4460550660

2-3 axle EBS 8418018200 2 with front axle valve, Train transport

4460550660

2 axles EBSE 8418020160 2 withcontrolbox&Unloadinglevelswitch

4460550660

2 axles EBSE 8418020180 2 withcontrolbox&battery 4460550660

2 axles EBSE 8418020190 2 with control box 4460550660

2 axles EBSE 8418022420 2 with front axle valve, without control box, with unloading level

4460550660

18


Device descriptionDiaphragm cylinder 423 XXX



Lifting axle(s)

Comment ECAS ECU

Connection of control box and remote control unit to ECASVCSII 8418017850VCS 8418018280EBS 8418018290

19

Device descriptionDiaphragm cylinder 423 XXX

5 Device description

ii

Thefollowingdevicedescriptionsaresortedbyproductnumber(first6numbers).

5.1 Diaphragm cylinder 423 XXX

Diaphragm cylinderforCamBrakes for disc brakes

Application

Drawbar trailer and semitrailer with more than one axle.

Brake chambers are used on the axles that do not have to be equipped with Tristop® cylinders.

Purpose

To generate the braking force for the wheel brakes. It can also be used to actuate other facilities, e.g. for clamping, raising or gear-shifting.

Maintenance

Special maintenance that extends beyond the legally stipulated inspections is not required.

Installation recommendation

– Install the diaphragm cylinder at an upward slant to the yoke joints so that any penetrating water can run out again.

– Make sure that the brake line is not lower than the cylinder heads when installing, so that the brake lineandtheconnectionpointswillnotbedamaged(bygroundcontact). Two couplings on the diaphragm cylinder simplify the line route, which can be used optionally by implementing the screw-plug. When installing the brake chambers or when adjusting the brake, the push-rod cannot be pulled out.

– Makesurethatthecylinderachievesitsidlepositionwhenthebrakeisreleased(thepistondoesnothangonthebrakeleverbutpressesthediaphragmagainsttherearwallofthehousing).

– Iftherodsofamechanicalparkbrakeassemblyalsoaffectthebrakelever,thenthepistonofthecylinderisnottobepulledoutpastaspecifiedstrokewhenactuatingthisassembly.Topreventdamages, use a yoke with an oblong slot.

20

Diaphragm cylinder 423 XXX Diaphragm cylinder 423 XXX

Installation diagram

1) 2)

LEGEND1) Restposition:noplay

permitted between piston and diaphragm

2) Operatingposition:atmaximum stroke

ii

The axle manufacturers recommend using the sealed version for trailing steering axles with verticallyinstalleddiaphragmcylinders(pistonrodpointsupwards):

Ordernumber24":4231069050(withaccessorykit)

21

Diaphragm cylinder 423 XXX

Installation dimensions – Diaphragm cylinder for the cam brake (with gaiter)

TYPE

Installation dimensions [mm]D1 D2 G1 H L1 L2 L3 L4 L5 L6 R1 R2 R3 X α

24 161 185 M16x1.5 120.7 27 34 96 113 134 85 112 15 45 96 19.5°36 – 230 M16x1.5 120.7 27 33 136 152 176 112 133 21.5 55 134 15°

Technical data – Diaphragm cylinder for the cam brake (with gaiter)

ORDER NUMBER 423 106 905 0* – TYPE 24 423 008 919 0** – TYPE 36

Max. stroke 75 mm 76mmVolume-strokeat2/3stroke 0.93litres 1.65litresTightening torque A 80±10NmTightening torque B 180+30NmTighteningtorqueC 45±5Nm 60±5NmAccessories pack 4230005332 –Weight 3.0kg 4.5 kgMax. operating pressure 8.5 barPermissible medium AirOperatingtemperaturerange -40°Cto+80°C

22


LEGEND1) withfordingcapability:Ventilationwith

pipe; supplied with accessories pack2) Thebrakechambertype36(threadM22x1.5)isdelivered

complete, with fastening nuts and screw plug, but with no yoke joint.Theyokejointcanbeorderedseparately(seechapter"Brakechamberaccessories"onpage27).

Installation dimensions – diaphragm cylinder for cam brake (with disc seal)

TYPE

Installation dimensions [mm]D1 D2 G1 H L1 L2 L3 L4 L5 L6 R1 R2 R3 X α

9 112 135 M 12x1.5 76.2 20 25 97 108 – 63 86 23 32 91 22.5°12 123 144 M 12x1.5 76.2 20 25.5 103 114 136 66 94 22 34 98 22.5°16 141 166 M 12x1.5 76.2 20 25.5 96 112 133 75 101 17 35 96 20.5°20 151 174 M16x1.5 120.7 27 34 96 112 134 80 105 15 45 96 20.5°24 161 185 M16x1.5 120.7 30 34.5 96 113 134 85 111 15 45 103 19.5°30 162 209 M16x1.5 120.7 27 34.5 104 113 134 92 123 15 45 102 30°

23


Technical data – Brake chamber for the cam brake (with disc seals)

ORDER NUMBER

423 102 900 0

TYPE 9

423 103 900 0

TYPE 12

423 104 900 0

TYPE 16

423 105 900 0

TYPE 20

423 106 900 0

TYPE 24

423 107 900 0

TYPE 30Max. stroke 60mm 75 mmMax. capacities at2/3stroke[litres]

0.28 0.40 0.75 0.85 0.93 1.15

Tightening torque A

80±10Nm

Tightening torque B

70+16Nm 180+30Nm

Tightening torqueC

– 40±5Nm

Ordernumber for "Round hole" accessories

4239025372 4239025332 4230005342

Ordernumber for "Slotted hole" accessory kit

4239025362 4239025342 4230005352

Gaiter Yes No

24


Pressure diagrams – Brake chamber for cam brake (with disc seals) Types 9 to 30

LEGENDF The average piston force is the force determined using

aniterationofthevaluesbetween1/3and2/3oftheoverallpistonstroke(hmax).

p Pressure in brake cylinder

h The usable piston stroke is the stroke at which the pistonforceis90%oftheaveragepistonforceF.

t Type

Type F [N] h [mm] hmax [mm]

9 606xp-242 0.64xp+44 6012 766xp-230 0.57xp+46 6016 1056xp-317 0.86xp+68 7520 1218 x p - 244 0.74xp+69 7524 1426xp-285 0.56xp+70 7530 1944 x p - 389 0.67xp+62 75

25


Installation dimensions – diaphragm cylinder for disc brake

LEGENDK Ball H Stroke

ORDER NUMBER TYPE Installation dimensions [mm] CONNECTIOND1 D2 L1 L2 L3 L4 L5 R1 α A B

4231147100 14 146 166 98 95 67 106 121 101 20° x 1)

4231047100 16 146 166 98 95 67 106 121 101 20° x x

4231047150 16 146 166 100 94 66 104 119 103 0° 1) x

4231047160 16 146 166 100 94 66 104 119 103 90° 1) x

4235040030 16 146 166 98 92 64 102 117 101 0° 1) x

4231127100 18 175 175 94 92 65 103 117 106 20° x x

4235050000 20 153 175 94 92 65 102 117 106 20° x x

4231107100 22 163 185 94 92 65 102 117 111 20° x x

4235060010 24 163 185 99 94 65 106 120 112.5 20° x x

LEGEND1) withscrewplugM16x1.5

26


Technical data – diaphragm cylinder for disc brake

TYPE 14 16 18 20 22 24

Max.deflectionofthepushrod 8°(with0mmstroke)Max. stroke 57 mm 62mm 64mmCapacitiesat2/3stroke[litres] 0.60 0.68 0.71 0.81Max. operating pressure 10bar 10.2barThermal range of application -40°Cto+80°CWeight 3.2 kg 2.8 kg 3.0kg

Test results – Brake chamber for disc brakes (types 14 to 24)

F The average piston force is the force determined using aniterationofthevaluesbetween1/3and2/3oftheoverallpistonstroke(hmax).

h The usable piston stroke is the stroke atwhichthepistonforceis90%oftheaverage piston force F.

TYPE F [N] h [mm] hmax [mm]14 861xp-255 1.40xp+40 5716 1062xp-308 0.54xp+46 5718 1138xp-330 1.19xp+47 6420 1210xp-351 1.00xp+55 6422 1332 x p - 373 0.79xp+50 6424 1453xp-407 0.57xp+48 64

Installation instructions – Brake chamber for disc brake

– Installthebrakechamberhorizontallysothattheopenedbreatherhole/drainholefacesdownward.Maximumdeviation:±30° Permissibledeviations:10°withpushrodshowingupward;30°showingdownwards.

– Be sure to remove the plastic plugs of the lower drain hole.

– FastenthebrakechamberwithnutsM16x1.5propertyclass8(WABCONo.8103040314)

– Thread on both nuts by hand until the brake chamber makes full contact.

– Thentightenbothnutstoapproximately120Nmandtightento210Nm(Tolerance-30Nm)with a torque wrench. If you are using self-locking nuts, the torque must be increased accordingly.

ii

Thepistonrodmustseatintheslotofthebrakeleverat/withmaximum10°deflectionofthepiston rod. Flange area and sealing surface of brake chamber and disc brake must be clean and undamaged.

The gaiter must have no damages and together with the back-up ring, being proper seated.

27


Brake chamber accessories

ITEM DESIGNATION ORDER NUMBER

423

000

531

242

3 00

0 53

2 2

423

000

533

242

3 00

0 53

4 2

423

000

535

242

3 00

2 53

0 2

423

103

532

242

3 90

1 53

3 2

423

901

538

242

3 90

2 53

2 2

423

902

533

242

3 90

2 53

4 2

423

902

535

242

3 90

2 53

6 2

423

902

537

242

3 90

3 53

0 2

1 Screw plug M16x1.5 8930117104 1 1 1 1 1 1 1 1 12 Ring seal A16x20 8114010574 1 1 1 1 1 1 1 1 13 Hexagon nut M 12 8103040264 2 2 2 2

M 12x1.5 8103040274 2 2 2 2 2 2M16x1.5 8103040314 2 2 2 2 2

4 Hexagon nut M 14x1.5 8103060134 1 1 1M16x1.5 8103190294 1 1 1 1 1 1 1 1

5 Yoke joint with bolt Ø 14

M16x1.5 8958013102 1 1 1 1M 14x1.5 8958013122 1 1

6 Yoke joint with bolt Ø 14

M16x1.5 8958015132 1 1 1 1M 14x1.5 8958015112 1M 14x1.5 8106120202

- Pins 14x45x35.6 8106011004 1 1 114x45x31.2 8106010974 112x45x34 8106010844 1

- Washer 15 8104030114 2 2 2- Split pin 4x22 8105110344 2 2 2 2 2

28

Line filter 432 500 Line filter 432 500

5.2 Line filter 432 500

Application

All trailers in the area of the coupling to the towing vehicle, for single- and dual-line brakes. If there are nofiltersalreadyintegratedinthehosecouplers,linefiltersareinsertedintothebrakelineandthesupply line.

Purpose

Protecting the compressed-air brake system from contamination.

Maintenance

– Cleanthelinefilter–dependingontheoperatingconditions–every3to4months.Removethefiltersetandblowitoutwithcompressedair.

– Replacethedamagedfilterinserts.


– Installthefilterwithbulkheadcouplingsinthepipesystem.

ii

Makesurethatthereissufficientspaceforremovingthefilterinsert(seefollowingfigure).

29

Line filter 432 500

Installation dimensions for 432 500 020 0

LEGEND1 Energysupply 2 Energy

discharge*) Spacerequiredforremovingfiltercartridge

Technical data

ORDER NUMBER 432 500 020 0 432 500 021 0

Max. operating pressure

20bar

Free passage Ø 12 mm = 1.13 cm2

Port threads M 22x1.5 M16x1.5Poresizeoffilter 80to140μmPermissible medium AirThermal range of application

-40°Cto+80°C

Weight 0.29kgRemark –

30

Vent valve 432 70X Knuckle joint 433 306

5.3 Vent valve 432 70X

4327000000 4327030000

Application

Installation in the exhaust opening of compressed air actuated brake and control devices.

Purpose

Damping exhaust noise.

Maintenance



– Installtheexhaustfilterinanoptionallocation. Sufficientspaceformounting/dismountingonthecompressedairdevice.

Installation dimensions for 432 700 000 0 and 432 703 000 0

Technical data

ORDER NUMBER 432 700 000 0 432 703 000 0

Port threads M 22x1.5 M 12x1.5Permissible medium AirThermal range of application

-40°Cto+125°C -40°Cto+120°C

Weight 0.03kg 0.02kg

31

Knuckle joint 433 306

5.4 Knuckle joint 433 306

Application

Vehicles with leaf-spring suspension. Knuckle joints are used in combination with mechanical LSV controllers.

Purpose

Prevents damages to load-dependent control valves or automatic brake force controllers, if the axle suspension is compressed or extended past the normal distance.

Maintenance


Installation regulations

– Choosetheknucklejointthatguaranteesthatthepathexceedingtheadjustmentrangeofthecontrollerisnotgreaterthanthepossibledeflectionh.

– Fortrailers–singleanddualaxle–takethedimensionforthedeflectionhfromthefollowingdiagram:

LEGENDh Deflection fmax Max.springdeflectionaccording

tothespecificationsoftheaxlemanufacturer

32

Knuckle joint 433 306 Knuckle joint 433 306

– Fasten the knuckle joint to the single axle or between the two axles of the dual-axle assembly based on the respective instructions of the axle manufacturer.

– Arrange the knuckle joint so that its ball joint is seated in the neutral point of the axle or axles. The"neutralpoint"isthepointthatisfreeofoutsideinfluence:

� Twisting movement of the axle during braking procedure

� Wandering in curves with steering axles

� One-sidedloadontheaxlewithunevenstreets

ii

Onlythestaticanddynamicaxlechangesarepermittedtobethereasonforadjustingtheautomatic load-sensing valve.

– ConnecttheknucklejointthrougharoundrodwithanM8threadandhexagonnutM8DIN934 (notincludedindelivery)withtheadjustmentleveroftheautomaticbrakeforcecontroller. The length of this connection rod depends on the mounting of the devices on the vehicle.

– Depending on the existing fastening capabilities for the connecting rod of the load-sensing valve to be used, either leave the connecting rod smooth or apply an M8 thread of approx. 25 mm in length.

– Screw an M8 DIN 934 hexagon nut onto the thread.

– Screw the other end of the connecting rod into the ball joint and secure it with the hexagon nut.

– Carefullytrimthesmoothendstopreventanydamagetotherubberthrustmembers.

33

Knuckle joint 433 306

Installation dimensions

Technical data

ORDER NUMBER LENGTH L [mm]

DEFLECTION h [mm]

DISPLACEMENT [N]F1 F2

4333060020 260 100 90 190

34

Linkage 433 401 Check valve 434 014

5.5 Linkage 433 401

4334010030

Application

If threaded onto the axle.

Purpose

Aflexiblerubberconnectionfortheguidingtheairsuspensionvalve464006XXXXoranECASheightsensor.


– Useaflatirontofastenthelinkageonthevehicleaxle. TheØ6pipefortheconnectionbetweenthetworubbersleeves(adjustmentleveroftheairsuspensionvalveandthelinkage)doesnotbelonginthescopeofdelivery.


35

Check valve 434 014

5.6 Check valve 434 014

Application

For multiple applications in compressed air systems.

Purpose

To protect the pressurised lines against unintentional venting.

Maintenance



– Install the valve anywhere in the piping.

ii

Payattentiontothearrowonthehousingthatshowsthedirectionofflowduringtheinstallation.


36

Check valve 434 014 Charging valve 434 100

Technical data

ORDER NUMBERS 434 014 000 0 434 014 001 0


20bar

Nominal diameter Ø 8 mm Port threads M 22x1.5Permissible medium AirThermal range of application

-40°Cto+80°C

Weight 0.17kgComment – Constantthrottling

Ø 1 mm

37

Charging valve 434 100

5.7 Charging valve 434 100

Application

Multiple applications in compressed air systems.

Purpose

Charging valve with backflowEnablingofthepassageforthecompressedairtothe2ndcompressedairreservoironlyafterthecalculation pressure of the braking system in the 1st reservoir has been reached; as a result, the service brake system is ready for operation more quickly.

Ifthepressuredropsinthe1stfirstreservoir,thereisafeedbacksupplyofairfromthe2ndreservoir.

Charging valve without backflowResidual pressure maintenance in lifting bellows of a lifting axle to prevent the bellows from wrinkling whentheliftingaxleislowered.Thepassingofcompressedairtoauxiliaryequipment(e.g.dooractuation,auxiliaryandparkingbrakingsystems,servoclutch,etc.)onlywhentheratedpressureforthe braking system has been reached.

Charging valve with limited backflowThepassingofcompressedairtootherconsumers(e.g.auxiliaryandparkingbrakingsystems)onlywhen the rated pressure for the braking system has been reached. Also the protection of pressure for the towing vehicle in the event of the trailer's supply line failing.

If the pressure in the air reservoirs for the service braking system drops, some of the compressed air flowsbackuntiltheclosingpressure(whichisdependentonthechargingpressure)isattained.

Maintenance



– Install the charging valve anywhere in the piping.

ii

Payattentiontothearrowonthehousingthatshowsthedirectionofchargeflowduringtheinstallation.

38

Charging valve 434 100 Two-Way Valve 434 208


CONNECTIONS1 Energysupply 2 Energydischarge

Technical data

ORDER NUMBERS 434 100 XXX 0Max. operating pressure 13 barNominal diameter Ø 8 mmPort threads M 22x1.5Permissible medium AirThermal range of application -40°Cto+80°CWeight 0.45kg

ORDER NUMBER VALVE TYPE CHARGING PRESSURE

(TOLERANCE -0.3 bar)4341000240 withbackflow 6.0bar4341000270 withbackflow 0.5bar4341001220 withoutbackflow 4.5 bar4341001240 withoutbackflow 5.5 bar4341001250 withoutbackflow 6.0bar4341001260 withoutbackflow 6.5bar4341002220 withlimitedbackflow 6.2bar

(Closingpressure=Chargingpressure

-15%)

39

Two-Way Valve 434 208

5.8 Two-Way Valve 434 208

Application


Towingvehicleexample:ActuationofbrakecylinderwithbrakingsystemorASRsystem.

Trailerexample:ControlofanotheraxlewithhigherbrakingpressureofTrailerEBS.

Purpose

The output pressure increase controlled from two separate inputs.

Maintenance



– Installthetwo-wayvalvewithconnections11and12horizontally(seeDIN74341)looseinthepipeline.


LEGEND2 Energy

discharge11 Energysupply 12 Energysupply G Thread

40

Two-Way Valve 434 208 Pressure switch 441 009 / 441 014

Technical data

ORDER NUMBER 434 208 029 0 434 208 028 0 434 208 050 0Max. operating pressure

10bar

Install dimension L 76mm 93 mmNominal diameter Ø 12 mm Ø10.5mmPort threads M 22x1.5 - 12

deep M16x1.5-12deep

Permissible medium AirThermal range of application

-40°Cto+80°C

Max. tightening torque 53 NmWeight 0.15kg 0.39kg

41

Pressure switch 441 009 / 441 014

5.9 Pressure switch 441 009 / 441 014

5.9.1 Pressure switch 441 009

Application

Multiple applications in compressed air systems. Separate housing, switches exclusively to ground.

Purpose

Thepressureswitchisusedforswitchingelectricaldevicesorindicatorlightsonoroff.

Maintenance



– Install the 1-pin pressure switch in any location in the pressure line.

– Fasten the pressure switch with one M8 bolt.

ii

Makesurethatfasteningismadetoapropergroundcontact(donotfastentoplasticparts).

– Attach a cable eyelet to the cable to be connected.

42

Pressure switch 441 009 / 441 014 Pressure switch 441 009 / 441 014


LEGENDX Adjusting screw

Technical data

ORDER NUMBER 441 009 001 0 ON SWITCH

441 009 101 0 OFF SWITCH

Max. operating pressure 10barActuating pressure setto5.0±0.2bar

canbeadjustedfrom1.0to5.0barPort threads M 22x1.5Max.operatingvoltage(DCvoltage)

30V

Max. electrical breaking capacity with inductive load and direct current

2 A

Permissible medium AirThermal range of application -40°Cto+80°CWeight 0.22kg

43

Pressure switch 441 009 / 441 014

5.9.2 Pressure switch 441 014

Application


Purpose

The pressure switch is used, depending on the version, for switching electrical devices or indicator lightsonoroff.


Technical data

ORDER NUMBER 441 014Max. operating pressure 12 barVoltage 12V/24VMax. electrical switching capacity at ohmic load

30W

Max. electrical switching capacity at relay load

5 W

Permissible medium AirThermal range of application -40°Cto+80°C

44

Pressure switch 441 009 / 441 014 Pressure sensor 441 044

Variants

ORDER NUMBER

SWITCHING PRESSURE (BAR)

TYPE COLOUR CONNECTION THREAD

4410140010 2.0±2.0 NOC Red X14410140020 1.0±0.2 NOC Red X34410140040 5.5±0.6 NCC Green X14410140050 2.0±0.2 NOC Red X34410140060 2.0±0.2 NCC Green X14410140070 3.0±0.3 NOC Red X34410140080 4.2±0.4 NCC Green X34410140090 4.0±0.4 NOC Red X34410140100 0.3±0.1 NCC Green X14410140120 3.5±0.4 NCC Green X14410140130 4.1±0.4 NCC Green X14410140140 4.5±0.5 NCC Green X14410140150 5.0±0.5 NCC Green X14410140170 4.0±0.4 NOC Red X14410140180 1.2±0.2 NCC Green X14410140190 0.15±0.1 NOC Red X14410140200 2.0±0.2 NCC Green X34410140210 0.5±0.15 NOC Red X14410140220 6.0±0.6 NOC Red X14410140230 2.5±0.3 NOC Red X14410140240 1.0±0.2 NOC Red X14410140250 6.0±0.6 NCC Green X14410140260 4.5±0.5 NOC Red X14410140290 5.0±0.5 NOC Red X14410140320 5.2±0.5 NCC Green X14410140400 3.0±0.3 NOC Red X14410140610 5.7±0.6 NCC Green X14410140720 6.6±0.6 NCC Green X14410140730 5.5±0.6 NOC Red X14410141000 0.15±0.1 NOC Red X24410141010 4.5±0.5 NCC Green X24410141020 5.5±0.6 NCC Green X24410141040 0.5±0.15 NOC Red X24410141050 5.7±0.6 NCC Green X2

45

Pressure sensor 441 044

5.10 Pressure sensor 441 044

Application

Multiple applications in compressed air systems for monitoring pressure.

Purpose

Conversionofapneumaticpressurevalveintoananalogueelectricalsignalthatcanbeevaluatedbycontroller electronics.

Technical data

ORDER NUMBER 441 044 102 0 Max. operating pressure 10barElectricalconnection Bayonet(DIN),

DIN72585-A1-3.1-Sn/K2Port threads M16x1.5Thermal range of application -40°Cto+80°CPermissible medium AirVoltage 8-32VDCSensitivity 400mV/barRing seal 8977702504Weight 0.03kg

46

Shut-off cock with venting 452 002 / 952 002 Shut-off cock with venting 452 002 / 952 002

5.11 Shut-off cock with venting 452 002 / 952 002

452002XXXX 952002XXXX

Application


Purpose

Shuttingoffcompressedairlines.

Maintenance



– Fastentheshut-offvalvewithtwoM8screws.

ii

Makesureoftheflowdirection(arrowdirection)wheninstallingandthatthereissufficientroom for actuating the lever.

47

Shut-off cock with venting 452 002 / 952 002


4520021310 9520020000

LEGENDView X

Technical data

ORDER NUMBER 452 002 131 0 452 002 132 0 452 002 133 0 952 002 000 0Max. operating pressure 10barPort threads M 22x1.5 - 12 deepLeveractuationa/b 90°Permissible medium AirThermal range of application -40°Cto+80°CWeight 0.26kg 0.58kg

SHUT-OFF COCK

90° LEFT 0° 90° RIGHT

4520021310 closed open closed4520021320 vented charged vented4520021330 closed charged vented9520020000 closed open closed

48

Dummy coupling with fastening 452 402 Duo-Matic quick-coupling 452 80X

5.12 Dummy coupling with fastening 452 402

Application

Semitrailer tractors and drawbar trailers.

Purpose

Holder for disconnected brake lines with coupling head.

Technical data

ORDER NUMBER 452 402 000 0 452 402 002 0For coupling heads 452200/952200 452201Weight 0.3kg

49

Duo-Matic quick-coupling 452 80X

5.13 Duo-Matic quick-coupling 452 80X

For drawbar trailers For semitrailers

Application

Connectionoftowingvehicleandtrailerinsteadofusinghosecouplers

Purpose

Connecttheairbrakingsystemofthemotorvehiclewiththebrakingsystemofthetrailer.

With Duo-Matic quick-couplings, the trailer vehicles can be coupled quicker and more securely than with standard coupling heads.

Maintenance



– InstalltheDuo-Maticquick-couplingaccordingtoISO1728(seefollowinginstallationdiagram).

50

Duo-Matic quick-coupling 452 80X Duo-Matic quick-coupling 452 80X

Installation diagram for drawbar trailers

Installation diagram for semitrailers

51


Installation dimensions for drawbar trailers

LEGEND1 Energysupply 4 Controlconnection A Vehicle part B Drawbar trailer part

52

Duo-Matic quick-coupling 452 80X Duo-Matic quick-coupling 452 80X

Installation diagram for semitrailers

LEGEND1 Energysupply 4 Controlconnection A Vehicle part B Semitrailer part

53


Technical dataORDER

NUMBERFOR DRAWBAR TRAILERS FOR SEMITRAILERS452 802 009 0

VEHICLE PART

452 804 012 0

DRAWBAR TRAILER

PART

452 803 005 0

SEMITRAILER PART

452 805 004 0

VEHICLE PART

452 802 007 0

SEMITRAILER PART

452 803 004 0

VEHICLE PART

Quick connector No No YesMax. operating pressure

10bar 10bar

Nominal diameter

9 mm 9 mm

Permissible medium

Air Air

Thermal range of application

-40°Cto+80°C -40°Cto+80°C

Weight 1.0kg 0.2kg 1.0kg 0.3kg 1.08kg 1.17 kg

54

Rotary slide valve 463 032 Rotary slide valve 463 032

5.14 Rotary slide valve 463 032

4630321XX0

Application

Air-suspension vehicles with conventional control. With air-suspension with suspension paths of>300mm,aversionofdeadmanswitchisrequired(variants4630321XX0).

Purpose

Controlofliftingandloweringair-suspensionvehicleswithahandlever.

Onvariantswithdeadmanswitch,thehandleverisautomaticallymovedbackintoidlepositionwhenitis released to prevent accidents.

Maintenance



– Install the rotary slide valve vertically so that the vent 3 points downward.

– Fasten the rotary slide valve with two M8 bolts.

– Attachtheprovidedsigndisplayingtheleversettingsunderthelever(seefollowinginstallationdimensionsaswell).

55

Rotary slide valve 463 032


View X

LEGEND1 Reservoir 3 Venting 21 Levelling valve *) Valvemarkedasclosed:By

pressing the button down, the blockage is released.

22 Air suspension bellows

23 Levelling valve 24 Air suspension bellows

56

Rotary slide valve 463 032 3/2 directional control valve 463 036


4630321200 4630321300

LEGEND* Stroke for park position

Technical data

ORDER NUMBER 463 032 020 0 463 032 120 0 463 032 130 0 463 032 220 0 463 032 023 0Max. operating pressure

10bar 8.5 bar 10bar

Nominal diameter 21,23=12.6mm2(Ø4mm)

22, 24 = 28.3 mm2(Ø6mm)

1,3=63.6mm2(Ø9mm)

1-circuit variant

21=12.6mm2

22 = 28.3 mm2

1,3=63.6mm2

Port threads M 12x1.5-12 deep

1=M16x1.5-12deep

M 12x1.5 -12 deep

1=M16x1.5-12deep

M 12x1.5 - 12 deep

Integrated check valve (port1)

yes no yes


-40°Cto+80°C

Max. actuation torque 7 Nm 9 Nm 7 Nm 7 NmWeight 1.4 kg 1.5 kg 1.4 kg 1.4 kgQuickfitconnections – – – 5x Ø8x1 –

57

3/2 directional control valve 463 036

5.15 3/2 directional control valve 463 036

Application

Multipleapplicationsincompressedairsystems.Switchingconnecteddevicesonandoffmanually.

Purpose

Alternatingtheconnectionsforoperationallines(devices)withthepressurelineortheventingline,whereby the valve is seated in both positions.

Maintenance



– Installthe3/2-wayvalveinthepipelinesystemsothatthevent3pointsdownward.

– Fastenthe3/2-wayvalveonabracket(holeØ28)withcounternutM28x1.5.


CONNECTIONS LEGEND1 Energysupply 2 Energydischarge 3 Venting * Ventilation begin

58

3/2 directional control valve 463 036 Lifting axle control valve 463 084

Technical data

Order number 463 036 016 0Max. operating pressure 10barPort threads M16x1.5-12deepforVOSSplug

connectionNominal diameter 4 mmPermissible medium AirThermal range of application -40°Cto+80°CWeight 0.25kg

59

Lifting axle control valve 463 084

5.16 Lifting axle control valve 463 084

5.16.1 2-circuit lifting axle control valve 463 084 0XX 0

4630840000

mechanical

4630840100

electric

4630840200

pneumatic

Application

Semitrailer or drawbar trailer with lifting axle.

ControlconventionalorviaECAS/TrailerEBS

Purpose

Theliftingaxlecompactvalveisresponsibleforloweringorliftingtheliftingaxle(s)manuallyandagainautomatically,assoonastheaxle(s)thataredownhavereachedtheirmaximumpermissibleload.

Maintenance



– FastentheliftingaxlecontrolvalveusingthethreestudboltsM6(A=tighteningtorque10Nm)orwithtwoboltsM8(B=tighteningtorque20Nm),seefollowingfigure"Installationposition". The unit is equipped with 9 mm holes for mounting.

Installation position

OptionallyA,B

Top view

OnlyA

Front view

60

Lifting axle control valve 463 084 Lifting axle control valve 463 084


LEGEND1) Lifting 2) Lowering

CONNECTIONS PORT THREADS1 Supply 3 Venting 1, 21, 22, 23, 24, 41 M16x1.520 Port lifting bellow 21, 23 Air-suspension

bellows "Vehicle"20 M 22x1.5

22, 24 Air-suspension bellows "Lifting axle"

41 Damping volume 42 M16x1.5(ISO3583)

42 Test valve for setting the switching pressures

61



4630840100 4630840200

LEGENDA Stud bolt B Screw

CONNECTIONS PORT THREADS1 Supply 3 Venting 1, 21, 22, 23, 24, 41 M16x1.520 Port lifting bellow 21, 23 Air-suspension

bellows "Vehicle"20 M 22x1.5

22, 24 Air-suspension bellows "Lifting axle"

41 Damping volume 42 M16x1.5(ISO3583)

42 Test valve for setting the switching pressures

62


Setting instructions

Afterthevalvehasbeeninstalledaccordingtothefixinginstructionandthescheme,theadjustmentofthe switch pressure has to be made.

www www

@

@ @@

circuit diagrams

– OpentheWABCOwebsitewww.wabco-auto.com.

– ClickonProductCatalogueINFORM=>Productnumber.

– Enterthenumberofthedesiredcircuitdiagramintothesearchfield.

– ClickontheStartbutton.

Figure 1 Figure 2

View Y

LEGENDa Provided cap b Setting range c Widthacrossflats12

M max. = 15 Nmd Lowering e Lifting f Endstopg corresponds with 5 full turns h Size2/

M max. = 1.5 Nmi Widthacrossflats10/

M=4±1Nm

http://www.wabco-auto.com

63


5.16.1.1 Mechanically actuated lifting axle control valve 463 084 000 0Seecircuitdiagram8418014480.

– Presstheactuationbutton(a).

– Set the switch pressure for lowering the lifting axle according to the pressure, at which it is made sure, that the permissible axle load is not exceeded. This is done by connecting a test hose with pressure gauge and pressure reduction valve with test connection 42.

Ö Thecompressedairflowsviaduct(f)intochamberB.Byincreasingthepressureofthetesthosetheswitchingpointonwhichtheactuationbuttonspringsoutisdetected,port20isgettingpressureless(liftingaxlelowers)andtheairsupplyofthebellowsontheliftingaxlesetsin.

– Youcanchangetheswitchingpressurewithsetscrews:Iftheswitchingpressureistoohigh,turnthe screw outward; if the switching pressure is too low, turn the screw inward. Whilecheckingthetestpressurealwayshastobeincreasedstartingfrom0bartoswitchoffthehysteresis.

– When the setting is completed successfully, counter-lock the adjustment screw and cover it with the provided cap.

5.16.1.2 Electrically actuated lifting axle control valve 463 084 010 0Seecircuitdiagram8418014470.

– Connectpressureswitch4410420000(settingrange1.0to5.0bar)accordingtothecircuitdiagram.

– Set the pressure switch in the same way as the mechanically actuated lifting axle control valve.

5.16.1.3 Fully automatic pneumatic lifting axle control valve 463 084 020 0Seecircuitdiagram8418014490.

Two switching pressures must be set.

– FirstremovetheprotectivecapwithanSW30spanner(M=45±5Nm).

– ThreadthePhilipsscrewJ(Size2)inwardtothestop(seefigure2).

– Settheswitchingpressureforloweringtheliftingaxle(screwK)withanAllenkey12mmthesameastheversionthatisactuatedmechanically(seefigure2).

– SettheswitchingpressureforautomaticliftingusingaPhilipsscrewdriver(size2).Thisrequiresloweringthetestpressureof8.0baragain.

Ö Thepressuredifferenceoftheswitchpressuresfortheautomaticloweringandraisinghastobe0.4barhigherthanthedifferenceinpressuresfortheairsuspensionbellowsbetweenliftedandnon-lifted axle.

Technical data


13 bar

Actuation mechanical electric pneumaticNominal diameter 7 mmPermissible medium Air


-40°Cto+80°C

Switching pressure setting "lowering"

2.5 to 7 bar – 2.5 to 7 bar

64


ORDER NUMBER 463 084 000 0 463 084 010 0 463 084 020 0Adjusted switch pressure

4±0.2bar – Lowering 4.5±0.2bar

Lifting2.5±0.2barAdjustable hysteresis

– – 1.5 to 4 bar

Voltage – 24 V +6V -4,4 V –Currenttype – Direct current –Nominal current – IN=0.22A –Weight 2.3 kgvehicle is being loaded

automatic lowering

automatic lowering

automatic lowering

vehicle is being unloaded

lift by pressing button

electric lifting automatic lifting

5.16.2 Single circuit lifting axle compact valve (spring-returned) 463 084 031 0

4630840310

Application

Semitrailerordrawbartrailerwithliftingaxle.ControlviaECASorTrailerEBS.Becauseofthesingle-circuit, only suitable for rigid trailer axles.

Purpose

Theconventionalliftingaxlevalveseries(spring-returned)hasbeenexpandedwiththesinglecircuitvariant.Oneliftingaxleisactuatedautomaticallydependingontheaxleload.The"Tractionhelp"functioncanalsobeactuatedbytheTrailerEBSorTrailerECASdependingonthecurrentaxleload.This variant can be used on rigid axles, for which the support bellows can be connected pneumatically fortheleftandrightvehiclesides.Herethespecificationsoftheaxlemanufacturermustbeobserved.

65



CONNECTIONS PORT THREADS11 Supply 12 Air-suspension

bellows "Vehicle"21 Port lifting bellow 11, 12, 21, 22 M16x1.5

22 Air-suspension bellows "Lifting axle"

31, 32 Venting

Technical data


13 bar

Nominal diameter Ø 8 mmPermissible medium AirThermal range of application

-40°Cto+80°C -40°Cto+65°C

Voltage 24V+6V/-6V

66


ORDER NUMBER 463 084 031 0 463 084 041 0 463 084 042 0Currenttype Direct currentNominal current IN=0.22AWeight 0.9kgQuickfitconnections – 4x Ø8x1 3x Ø8x1

1x Ø12x1.5www www

@

@ @@

TheelectricalconnectiontotheTrailerEBSorECASismadeviasystemcables,seeCableOvervieworECASSystemDescription/EBSSystemDescriptionformoreinformation.


– ClickonProductCatalogueINFORM=>Index.

– EnterEBS,ECASorOverview.


Tolowertheliftingaxle,thecurrenttothesolenoidcoilisinterruptedandarmature(d)closesinlet(c).Thecompressedairuponpiston(a)isexhaustedviasolenoidcoilandvent32.Thecompressionspringraisespiston(a)andtheliftingaxlecontrolvalveisbackinitsinitialpositionwheretheportsareconnected; 12 with 22 and 21 with 31.

If the lifting axle valve for the traction help is used with residual pressure maintenance in combination withTrailerEBS,theventmustberemoved.Todothis,alineisroutedfromtheventtothe3/2-waysolenoidvalveforresidualpressuremaintenanceandportIN/OUT1ofthemodulatormustbeconnectedviacable449764XXX0.Theliftingaxlevalvevent(connection3)isshutoffbyatwo-wayvalve,ventedaccordinglybytheTrailerEBSmodulatorandthemaximumpossiblebellowspressureismaintained. The traction help can be activated by a button.

Seecircuitdiagram8418021910.

5.16.3 Two-circuit lifting axle control valve (pulse-controlled) 463 084 100 0

Application

Semitrailerordrawbartrailerwithliftingaxle.ControlviaTrailerEBSandECAS.EnablesTractionHelp,dynamicwheelbasecontrolandimmobilizerfunctionality.

Purpose

With pulse-controlled valves, a special lifting axle actuation is possible, e.g. the lifting axle can be kept intheraisedpositionaftertheignitionisswitchedOFF.Thisisnotpossibleusingspring-returnedliftingaxle valves.


67


Technical data

ORDER NUMBER 463 084 100 0Max. operating pressure 13 bar Nominal diameter Connection1,21,22(Ø10mm);

Connection23,24,25(Ø8mm);Connection32(Ø8.7mm)

Permissible medium AirThermal range of application -40°Cto+65°CVoltage 24 +6V -4,4 V

Currenttype Direct current Nominal current IN=0.34AWeight 2.3 kg

68

TASC – Return-to-Ride valve 463 090 TASC – Return-to-Ride valve 463 090

5.17 TASC – Return-to-Ride valve 463 090

4630900120 4630900200 4630900210

Application

Forair-suspensioncommercialvehicleswithTrailerABSorTrailerEBS.

Purpose

TASCcanbeusedtoraiseandlowerthevehicle–inthesamewayaswitharotaryslidevalve. The chassis is also automatically returned to normal driving level as soon as the vehicle starts driving (RTR–Return-To-Ride).

Thelifting/loweringprocessisstartedbysimplyturningthehandlerightorleft.Tohaltthisprocessthehandle is moved back into the stop position. The system keeps the chassis at the set level.

TASCcanbeoperatedincombinationwithorwithoutlevellingvalvewithheightlimitation.TASCcanbe connected directly if levelling valves with height limitation are used. This avoids the bellows being permanently connected to the air reservoir at the upper stop position.

Handle positions

Lowering Stop Drive Stop Lifting

Returntonormaldrivinglevel(RTR) Locking in lowering Dead-man's safety system

69

TASC – Return-to-Ride valve 463 090

Maintenance


Installation

TASCcanbefittedtotheoperatingpanelonthetrailer.

Dependingontheclearance,theunitcanberotatedthrough90°oninstallation.TheTASChandlecanthen be turned accordingly so it is easy for the user to operate.

ii

Electricalconnection TASCwithReturn-to-RideiscontrolledbyaspeedpulsefromtheABS-/EBSsystem.RetrofittingTASC(whenreplacingarotaryslidevalveorsimilarproduct)mayrequireadiagnostictoolaswellastrainingforthenewsystem.OneofthecableslistedbelowisrequiredforWABCOsystems.

CABLE SYSTEM LENGTH449623XXX0 VCSII 6m/6m;10m/10m4494350300 EBSD 3 m449443XXX0 EBSE 0.8m;1m;2m;4m;6m;10m

70

TASC – Return-to-Ride valve 463 090 TASC – Return-to-Ride valve 463 090

Technical data

PART NUMBER 463 090 020 0 DUAL CIRCUIT

463 090 021 0 DUAL CIRCUIT

463 090 023 0 DUAL CIRCUIT

463 090 123 0* DUAL CIRCUIT

463 090 012 0 SINGLE CIRCUIT

RTR function x x x x xLocking in lowering position

x x x – x

Pneumatic connection

8x1 8x1 M16x1.5 M16x1.5 M16x1.5

Test connection x – – – xOperatingpressure 3.5…10barVoltage 18 ... 32 VThermal range of application

-40…65°C

Electricalconnection DIN72585-B1-3.1-Sn/K2-bayonet

LEGEND* Dead-man'ssafetysystemforvehicleswithastrokeexceeding300mm

Housing lever adjustment

23

41

LEGEND1 TASC 2 Pin 3 Lever 4 Screw

71

TASC – Return-to-Ride valve 463 090

72

Damping reservoir 463 084 020 2 Test connection 463 703

5.18 Damping reservoir 463 084 020 2

Application

Mainlyusedincombinationwiththeliftingaxlecontrolvalves4630840000,4630840100and4630840200.

thedampingreservoirisalowcostsolutionsinceitisdirectlyfittedtoport41ofliftingaxlecontrolvalves.

Purpose

In order to prevent accidental lowering of the lifting axle, if e.g. only because of road irregularities, the switchingpressureforloweringtheliftingaxleisachievedbriefly,adampingvolumeisrequired.

Technical data

ORDER NUMBER 463 084 020 2Volume 1 dm3

Ambient temperature -40°Cto+60°CMax. operating pressure 8.5barat60°C

10barat40°CTightening torque 26+4 NmMaterial PlasticColour BlackMale stud thread M16x1.5Installation position Optional


73

Test connection 463 703

5.19 Test connection 463 703

Application

Allvehicles.Canbeusedoncontrolandbrakelines.

Purpose

Temporary connection of pressure measurement devices for testing systems or certifying vehicles.

Maintenance

– Checkvalveregularlyforproperclosing.

74

Test connection 463 703 Levelling valve 464 006


ORDER NUMBER D1 D2 L1 L2 L3 L4 SW 1 SW 2 SW 3 FIG.4637000020 M 18x1.5 – 46.3 22.5 – – 22 – – 14637030050 10x1* 10x11) 60 30 30 49 19 19 17 44637030070 12x1.5* M 12x1.5

1)64 32 32 51 22 22 17 4

4637030240 8x1* M 12x1.5 65 28 33 52 17 17 – 44637031140 M16x1.5 – 36 9 – – 22 – – 14637033010 12x1.5* M 22x1.5 96 45 51 42 27 27 17 34637033030 M 22x1.5 M 22x1.5 96 42 54 42 27 27 17 34637033060 12x1.5* M16x1.5 94.5 33 61.5 37 22 22 17 34637051030 M 22x1.5 – 36 10 – – 27 – – 14637033160 3/8"-18NPTF – 45 14 – – 19 – – 14637039950 M 12x1.5 – 43 7 – – 17 – – 24637051050 M16x1.5,

1:16

Coned

– 36 10 – – 17 – – 1

LEGEND* Outerdiameterxwallthickness

75

Levelling valve 464 006

5.20 Levelling valve 464 006

Application

Vehicles with conventionally controlled air-suspension.

Purpose

Adjustingtheleveltoaconstantchassisrideheightbyair-springairintakewhencompressing(loadingthevehicle)andbyventingthemwhendecompressing.Theheightismeasuredviatheangleofthelever that is connected to the axle over linkage.

Heightlimitation:Thelevellingvalves4640061000,4640061010and4640062010haveanadditional3/2-wayvalvethatclosesasofacertainadjustableleverangleandswitchestoaventingfunction upon actuating the lever again. This "Height limitation" prevents the vehicle from being raised above a permitted level with the rotary slide valve.

Zeropointadjustment:Therideheightcanbeadaptedtospecialapplicationconditionsofthevehiclewith an operating cylinder integrated in the linkage.

Maintenance


76

Levelling valve 464 006 Levelling valve 464 006


LEGEND1) Vent 2) Operatingrange 3) Charge 4) Fixing the valve in end position with

≥7barsupplypressureand≤3barbellowspressure by inserting a Ø3h8 locator pin or a Ø3h8 x 24 DIN7 parallel pin

CONNECTIONS PORT THREADS1 Energysupply

(Reservoir)3 Venting 21/22 Energydischarge

(Airsuspensionbellows)M 12x1.5 - 12 deep

77



View X

CONNECTIONS PORT THREADS1 Energysupply

(Reservoir)3 Venting 12 Energysupply

(Supply)1 21 22 M 12x1.5 - 12

deep21/22 Energydischarge

(Airsuspensionbellows)

23 Energydischarge(Rotaryslidevalve)

12, 23 M16x1.5

78

Levelling valve 464 006 Levelling valve 464 006

Levelling valve 464 006 XXX 0 – Linkage 433 401 003 0

Thelinkage4334010030mustbeorderedseparately.

LEGENDα Deflectionofthe

levelling valve lever max.45°.

A A is the dimension between axle mounting point and the connection to the levelling valve lever (α-character).

L Leverlength(atleast150mm)

For adjusting the valve at the vehicle it is decisive which total spring travel the axle permits.

Approximate value:Theratio"leverlengthL/rodlengthA"shouldbe≤1.2iftheclosingangleofmaximum45°isnotexceeded.

TheleverlengthLshouldbe150to295mm.Ifashorterleverhastobeused,ahigherairconsumptionof the levelling valve has to be concerned.

Installation recommendation and setting information

– FastenthelevellingvalveverticallyorhorizontallywithtwoM8boltsonthechassis. If installed vertically, the exhaust must point to the bottom. Ifinstalledhorizontally,theexhaustmustpointtothedrivingdirection(towardstherearofthevehicle).

– To make installation and setting of the lever and linkage easier, you can insert a Ø 3h8 locator pin or a Ø 3h8 x 24 DIN 7 parallel pin into neutral position to position the air-suspension valve shaft (seepreviousinstallationdimensions).

– Install the linkage if the vehicle is positioned at normal level.

Ö The linkage has to be aligned vertically.

– Mount the levelling valve at maximum lever length if possible.

79


– You can clamp the lever at the desired length with the hexagon head bolt seated on the fastener for the round bar. Depending on the installation position, various cranks of the lever are possible.

– Byaccordinglyfixingorturningtheleverfor180°thelevellingvalvecanbeoptionallyoperatedfrom right or left.

– Dependingonthefinalinstallationposition-verticalorhorizontal-theleveristobeinsertedthroughoneofthetwoboresintheoperatingshaftwhichareoffsetby90°tooneanother. Thelevellingvalve4640061000issettoaclosingangleof30°±2°inthefactory. Thesettingadjustmentsliebetween15°and45°.Aclosingangleof<15°isnotpermitted.

ii

Note the adjustment data of the vehicle manufacturer when replacing.

– Foradjustmentoftheclosingangletherubberplugunderneaththe3/2-DirectionalControlValvehastoberemovedtoadjusttheadjustingscrewwithaTorxT30screwdriver. Counterclockwisemeansareductionoftheclosingangle,clockwisemeansanincrease. Onerotationmeansanapprox.13°anglechange.

Thefollowingtablecanbeusedtodefinetheheightincreaseofthevehicleuptoshuttingthesupplyairofftotherotaryslidevalveasafunctionoftheclosingangleandfordeterminingtheleverlength.

– Afterthevehiclehasbeenloweredtoitsbufferswiththehelpofarotaryslidevalve,measuretheheight of the chassis.

– Then raise the chassis with the rotary slide valve.

Ö If the permissible full suspension travel is achieved before the height limitation of the levelling valve is applied, cancel the raising process and lower the vehicle. Turning the set screw counterclockwise reduces the closing angle and also the suspension travel. If the height limitation sets in before the chassis is at the required hub height, the vehicle has to be lowered slightly as well in this case. Turning the self-locking set screw clockwise increases the closing angle and the suspension travel. Repeattheprocessuntiltherequiredsuspensiontravel(equalorlessthanthemaximumsuspensiontravelspecifiedbytheaxlemanufacturer)isachieved.


LEVER LENGTH L [mm]

STROKE HEIGHT H [mm]α = 15° α = 20° α = 25° α = 30° α = 35° α = 45°

125 32 43 53 62 72 88150 39 51 63 75 86 106175 45 60 74 87 100 124200 52 68 84 100 115 141225 58 77 95 112 129 159250 65 85 106 125 143 177275 71 94 116 137 158 194295 76 101 125 147 169 209

STROKE HEIGHT H [mm]

LEVER LENGTH L [mm]α = 15° α = 20° α = 25° α = 30° α = 35° α = 45°

50 193 146 118 100 87 7160 232 176 142 120 105 85

80

Levelling valve 464 006 Plug-in couplings for levelling valves 893 000

STROKE HEIGHT H [mm]

LEVER LENGTH L [mm]α = 15° α = 20° α = 25° α = 30° α = 35° α = 45°

70 271 205 166 140 122 9980 309 234 189 160 140 11390 263 213 180 157 127100 293 237 200 174 141110 260 220 192 156120 284 240 209 170130 308 260 227 184140 280 244 198150 300 262 212160 279 226170 297 241180 255190 269200 283

Technical data

ORDER NUMBER 464 006 002 0 464 006 100 0 464 006 101 0 464 006 102 0 464 006 201 03/2directionalcontrol valve

no yes yes no yes


13 bar

Max. dynamic bellows pressure

15 bar

Permissible medium

Air


-40°Cto+80°C

Linkage RoundleverØ6mmNominal width Levelling valve

2x Ø 3 mm

Nominal width Shut-offvalve

– Ø6mm – – –

Weight 0.41kg 0.51kg 0.51kg 0.53kg 0.70kgQuickfitconnections – – – 5x Ø8x1 5x Ø8x1

ii

Forthezeropointadjustmentonthelevellingvalve,thefollowingoperatingcylinderscanbeused:

� 4214100230,stroke25mm

� 4214100540,stroke45mm

� 4214113040,stroke85mm;withpistonrodfacingupward,usebellows(Accessoriespack4214115302)

81

Plug-in couplings for levelling valves 893 000

5.21 Plug-in couplings for levelling valves 893 000

8930000582 8930000782

Application

Vehicles with composite variants of the trailer chassis levelling valves.

ORDER NUMBER NAME PORT THREADS

8930000582 T-pieces 8x1

8930000782 Angle 8x1

Compatibility

BASIC HEIGHT LIMITATION

4640065000

4640065400

4640065800

4640065200


893 000 058 2 893 000 078 2

82

3/2 directional control valve 472 1XX 3/2 directional control valve 472 1XX

5.22 3/2 directional control valve 472 1XX

Venting3/2-waysolenoidvalves Charging3/2-waysolenoidvalve

Application

Multiple applications, i.e. controlling operating cylinders.

Purpose

Venting3/2-waysolenoidvalve:Toventanairlinewhencurrentissuppliedtothesolenoid.

Charging3/2-waysolenoidvalve:Topressuriseanairlinewhencurrentissuppliedtothesolenoid.

Maintenance

No special maintenance is required.


– Installthe3/2directionalcontrolvalveinanyposition.

– Fastenthe3/2directionalcontrolsolenoidvalvewithtwoM8screws.

– Ifsolenoidswithoutanyprotectivecircuitryarebeingused,usediodeplug8941016202.

ii

Intrailerswhichhaveelectronicsystems(e.g.ABS,ECAS)fitted,nosolenoidvalvesmaybeinstalled without protective wiring if they have the same source of power as the electronics.

83

3/2 directional control valve 472 1XX


Venting3/2-waysolenoidvalves4721020400 4721717260

LEGEND1 Energysupply 2 Energydischarge A Loosen the SW 19 hexagon nut to

turn the magnets

3 Venting 4, 6 Electricalcontrolconnection

84

3/2 directional control valve 472 1XX 3/2 directional control valve 472 1XX

Charging3/2-waysolenoidvalves4721271400 4721706060

LEGEND1 Energysupply 2 Energydischarge A To turn the magnets, loosen the

knurled nut.

3 Venting 4, 6 Electricalcontrolconnection

CablewithDINbayonet449515XXX0

Length L on request

Technical data

ORDER NUMBER VENTING 3/2-WAY SOLENOID VALVES472 102 040 0 472 171 700 0 472 171 726 0 472 173 226 0 472 173 700 0

Operatingvoltage

(DC)

10.8Vto28.8 V

24 +8-6,5 V

Nominal diameter

Charging Ø2.6mm Ø 2.2 mm Ø 4 mmVenting Ø 2.2 mm

Nominal current at10.8V=0.33A

at 28.8 V = 0.87A

0.41A 0.69A

85

3/2 directional control valve 472 1XX

ORDER NUMBER VENTING 3/2-WAY SOLENOID VALVES472 102 040 0 472 171 700 0 472 171 726 0 472 173 226 0 472 173 700 0

Duty cycle 100%cut-out voltage – <I65IV <I80IVPort threads 2, 3 = M 12x1.5

-10deepM 12x1.5 1 = M 12x1.5 - 7

deep

2, 3 = M 12x1.5 -10deep

M12x1.5-10deep

M 12x1.5


8 bar 11 bar


-40°Cto+70°C -40°Cto+100°C -40°Cto+80°C

Connector M 27x1 DIN bayonet M 27x1Weight 0.6kg 0.5kg

ORDER NUMBER CHARGING 3/2-WAY SOLENOID VALVES472 127 140 0 472 170 600 0 472 170 606 0 472 172 600 0 472 172 626 0

Operatingvoltage

(DC)

10.8Vto28.8V 24 V +8 -6,5

Nominal diameter

Charging Ø 2.2 mm Ø 4 mm Ø 2.2 mm Venting Ø 3 mm

Nominal current at12V=0.33A

at24V=0.65A

0.69A 0.41A

Duty cycle 100%cut-out voltage – <I80IV <I65IVPort threads M12x1.5-10

deep M 12x1.5 M12x1.5-10

deep M 12x1.5 M12x1.5-10

deep Max. operating pressure 8.5 bar 10.2bar 11 barPermissible medium AirThermal range of application

-40°Cto+70°C -40°Cto+80°C -40°Cto+100°C

Connector – M 27x1 DIN bayonet M 27x1 DIN bayonetWeight 0.5kg

86

Pressure reduction valve 473 301 Pressure reduction valve 473 301

5.23 Pressure reduction valve 473 301

4733010020

Application

Multiple applications, e.g. reducing braking pressures on a trailing steering axle.

Purpose

Reducing the input pressure in a certain ratio, and quick venting of the downstream brake unit.

Maintenance



– Install the pressure reducing valve vertically so that the drain 3 points downward.

– Fasten the pressure reduction valve with two M8 screws.


CONNECTIONS1 Energysupply 2 Energydischarge 3 Venting

87

Pressure reduction valve 473 301

Technical data

ORDER NUMBER 473 301 000 0 473 301 001 0 473 301 002 0 473 301 003 0Pressure reduction ratio 2:1 1.5:1 1.35:1 1.15:1Port threads M 22x1.5 - 15 deep Max. operating pressure 10barPermissible medium AirThermal range of application -40°Cto+80°CWeight 0.9kg

Diagram

LEGENDp1 Outputpressure p2 Input pressure

88

Quick release valve 473 501 / 973 500 Quick release valve 473 501 / 973 500

5.24 Quick release valve 473 501 / 973 500

47350100X0

9735000XX0

4735010040

Application

Vehicles with long brake lines and large-volume brake cylinders.

Purpose

Rapid evacuation of longer control lines or brake lines and brake cylinders. The brake is therefore released without a delay.

Maintenance



– Install the quick release valve so that vent 3 points downward.

– Fasten the quick release valve with two M8 bolts.

89

Quick release valve 473 501 / 973 500


CONNECTIONS PORT THREADS1 Energysupply 2 Energydischarge 3 Venting M 22x1.5 - 13 deep

90

Quick release valve 473 501 / 973 500 Quick release valve 473 501 / 973 500


CONNECTIONS PORT THREADS11, 12 Energysupply 3 Venting 3 11 12 M 22x1.5 - 13 deep

2 Energydischarge 2 M16x1.5-13deep

91

Quick release valve 473 501 / 973 500



Technical data

ORDER NUMBER 473 501 000 0 473 501 001 0 473 501 004 0 973 500 000 0 973 500 051 0Port1,2withfilter no no yes no noMax. operating pressure

10bar 12 bar

Nominal diameter Ø 14 mmPermissible medium AirThermal range of application

-40°Cto+80°C

Weight 0.3kg 0.43kg

92

Pressure limiting valve 475 010 Pressure limiting valve 475 010

5.25 Pressure limiting valve 475 010

4750103XX

Application

Multiple applications, on a lifting axle e.g. for limiting the pressure on the lifting bellows.

Purpose

To limit the output pressure to a set level.

Maintenance



– Install the pressure limiting valve vertically so that the vent 3 points downward.

– Fasten the pressure limiting valve with two M8 screws.



93

Pressure limiting valve 475 010

Technical data

Max. operating pressure 20barPort threads M 22x1.5 - min. 12 deepPermissible medium AirThermal range of application -40°Cto+80°CWeight 0.37kg

ORDER NUMBER INPUT PRESSURE p1

OUTPUT PRESSURE p2

SETTING RANGE AT p1 = 7.5 bar

4750103020

7.5 bar

5,3+0.3bar 1.5-6.0bar4750103030 1,8+0.3bar 1.5-6.0bar4750103050 6,0+0.3bar 6.0-7.5bar4750103090 5,7+0.3bar 1.5-6.0bar4750103100 4,0+0.3bar 1.5-6.0bar4750103120 5,5+0.2bar 1.5-6.0bar4750103130 3,3+0.3bar 1.5-6.0bar4750103070

8.0bar1,8+0.3bar 1.5-6.0bar

4750103240 1,4+0.3bar 0.5-1.6bar4750103110 8.5 bar 3,5+0.3bar 1.5-6.0bar

94

Load sensing valve (LSV) 475 71X Load sensing valve (LSV) 475 71X

5.26 Load sensing valve (LSV) 475 71X

5.26.1 LSV 475 712

Application

LSVcontrollerwithintegratedtrailerbrakevalveforleaf-springsemitrailers(mainlyinItaly,FranceandtheUK)

Purpose

Controlofthetwo-linetrailerbrakingsystemswhenactuatingthebrakingsystemofthetowingvehicle.Automatic control of the braking force based on the load status of the vehicle with the integrated LSV. Actuation of the automatic trailer braking with partial or total pressure drop in the supply line.

Maintenance



– Install the LSV vertically so that the vent points downwards. The setscrews on the top of the housing are used for fastening. Forthelinkage,useknucklejoint4333060030ifnecessary.

– To determine the lever length L, draw a line in the respective nomograph using the scale for control ratioi(e.g.2.8)tothescaleforspringdeflectionf(e.g.30).

Ö ExtendingthislinecrossesthescaleforleverlengthLat140mm.

95

Load sensing valve (LSV) 475 71X

Nomograph

1.5

1.6

1.7

1.8

1.9

2.0

2.2

2.4

2.62.83.0

3.5

4.04.55.0

6.07.07.58.08.4

i

f (mm)

15

20

25

30

35

40

50

55

6065707580859095100

45

50

55

60

65

70

75

80

85

90

95

100

110

120

130

140

150

160

170

180

190

200

210

220230

240250

L (mm)

LEGENDi Controlratio=

pon-0.8/poff-0.5f Springdeflection L Lever length

96



CONNECTIONS PORT THREADS LEGEND1-2 Energysupplyorrelease

(supplyreservoir)1, 4 M16x1.5-12deep 1) Endstopatlinkagebreak

1 Energysupply 1-2 M 22x1.5 - 13 deep 2) Overstroke2 Energydischarge 2 M22x1.5-13deep(side) 3) Controlstroke3 Venting 2 M16x1.5-122deep

(bottom)4) Endstop

4 Controlconnection

97


Technical data

ORDER NUMBER 475 712 000 0 475 712 004 0Max. operating pressure 10bar

Controlrange,dynamiceffect α=20° α=30°

Usableleverlength 50to290mm 50to275mmLinkage vialinkage(see

Fig. "Installation Dimensions")

with integrated knuckle joint, see 475 713

Port1,1-2,4withfilter – XMax. permissible adjustment torque M2 20Nm

Thermal range of application -40°Cto+80°C

Weight 2.2 kg 2.6kg

98


Pressure diagrams

4757120000

4757120040

Automatic braking

LEGENDp1 Input pressure p4 Controlpressurep2 Outputpressure α Lever travel [degrees]

99


5.26.2 LSV 475 713

Application

StaticLSVformechanicalsuspensionvehicles(single-axles/axleassemblies)withoutEBS.

With axle assemblies, only in combination with trailer brake valve or relay valve to meet timing requirementsinaccordancewithECER13.

Purpose

Automatic control of the braking force in pneumatic brake cylinders depending on the vehicle’s load status.

100



CONNECTIONS PORT THREADS LEGEND1/4 Energysupply 1/4 M 22x1.5 - 13

deep1) Endstopatlinkage

break3) Controlstroke

2 Energydischarge

2 M16x1.5-12deep

2) Overstroke 4) Endstop

3 Venting

101


Setting instructionswww www

@

@ @@

Loadsensingvalveprogram(LSV)

The required lever length can be also determined with our calculation program instead of using nomographs.


– ThenclickonthelinksServicesandSupport=>WABCOWorkshopSolutions=>DiagnosticsDownloadCenter=>WABCOLSV.

ThenomographsbelowareusedtodeterminetheLSVleverlengthstobesetontheunit.Usinganadjustment tool and a Ø 3 mm pin, you can set the empty braking pressure at a certain input pressure (e.g.6bar)andclampwiththeboltSW10.BeforeadjustmentscanbemadeonLSV(cablelength,leverposition,etc.),thereistobenopressureontheLSV.

AfterfittingtheLSVinthevehicle(empty)andtheknucklejointontheaxleshaft(Intheprocess,thespringoftheknucklejointhastobeprestressedby15mmusingthefasteningbolt)andaftertighteningandfixingtheconnectingcable(cablelengthMin.50mm,Max.450mm),theconnectingcablemust hang vertically below its fastening on the lever. When the pin is removed and the LSV is again pressurised, its output pressure must be the LSV unladen pressure.

Makesmallcorrectionstotheunladenbrakingpressurebythreadingthefasteningboltinorout(max.5mm).Iftheunladenbrakingpressureiscorrect,theknucklejointisprestressedorincreasedbythesumofthesuspensiontravelofthetrailer(pathdifferentialloaded–unloaded).WhentheLSVischarged again, it must output the input pressure. If the output pressure is less than the input pressure, either the lever is too long or the suspension travel is too short. In the case of the output pressure being thesameastheinputpressure,theleverisloweredbyapprox.10%ofthespringexcursiontowards"empty". The resulting output pressure must be less than the input pressure. If this is not the case, either the LSV lever is too short or the suspension travel is too great.


102


Nomograph for LSV475 713 500 0

Nomograph for LSV475 713 501 0

i

f (mm)

L (mm)

1.5

1.6

1.7

1.8

1.9

2.0

2.2

2.4

2.6

2.83.0

3.5

4.04.55.05.56.06.57.07.58.08.5

12

15

20

25

30

35

40

45

50

556065707580859095100

50

55

60

65

70

75

80

85

90

95

100

110

120

130

140

150

160

170

180

190

200

210

220230

240250260270280

i

f (mm)

L (mm)

1.5

20

50

60

65

70

75

80

85

90

95

100

110

120

130

140

150

160

170

180

190

200

210

220230

240250260270

1.6

1.7

1.8

1.9

2

2.2

2.4

2.6

2.83

3.5

4

5

6

77.5

25

30

35

40

45

50

55

6065707580859095100

110120130140150160170180190200

LEGENDi Controlratiopon-0.8/poff-0.5 f Springdeflection L Lever length

103


Technical data

ORDER NUMBER 475 713 500 0 475 713 501 0Max. operating pressure 10barMax. control ratio 8:1Nominal diameter Ø10mmMax. permissible adjustment torque M2

20Nm

Controlstroke α=20° α=33°Thermal range of application -40°Cto+80°C

Weight 1.8 kg

Pressure diagrams

4757135000

4757135010

LEGENDp1 Controlpressure p2 Outputpressure α Lever travel

[degrees]

104


5.26.3 LSV 475 714

Application

Staticcontrollerforair-suspensionvehicleswithoutEBS.

Purpose

Automaticcontrolofbrakingpressurefromairbrakecylindersonair-suspensionaxles(axleassemblies)dependingonthecontrolpressureoftheair-suspensionbellows(air-bags).

Maintenance

– To test the LSVs, fasten a test hose to connection 43.

Ö Screwingonpressesthepiston(n)intothehousing,therebyinterruptingconnections41and42tothepistons(mandk).Atthesametime,acompressedairconnectionfromconnection43tothepistons(mandk)iscreated.Inthisstate,theLSVsetsitselftoacontrolpositioncorresponding to the air pressure in the test hose.


– Fasten the LSV onto the frame of the vehicle so that vent 3 faces downward.

– Makeconnections41and42withtheair-suspensionbellows(air-bags)ontherightandleftvehiclesides.

105



LEGEND* When releasing the air from the device, air can escape at the sealing surfaces.

106



@

@ @@





DescriptionofthenomographsIandIIforsettingtheLSVs4757145000:

Nomograph I for determining the compression spring and spring length L1

LEGENDi pon-0.8/poff-0.5 S2 Screw 896 512 360 4 Compressionspring

(wireØ4mm)ΔpL Air cushion - pressure

differential;

Unladen-Laden

D Spacer 896 512 370 4 Compressionspring

(wireØ3.2mm)


107


Nomograph II for determining the screw setting length L2 and the spacers N as well as L3

LEGENDL1 Spring length N Number of spacers H1 Reference

line 1896 512 370 4 Compression

springL2 Screw length i Controlratio

(pon-0.8)/(poff-0.5)H2 Reference

line 2896 512 360 4 Compression

springL3 Unladenstopbolt

(W)p41/p42 Air cushion pressure

"unladen"

Determining the compression springs and setting length L1

REQUIRED ADJUSTMENT VALUESpon(p1)=6.5bar pBellows laden = 4.1 bar

pBellows unladen=0.2bar poff = p2 unladen = 1.75 bar

– Calculatingthecontrolratio:

i=(pon-0.8)/(poff-0.5)=(6.5-0.8)/(1.75-0.5)=4.56

– EnterthecontrolratioinnomographsIandII(pointA).

– Inaddition,marktheaircushionpressuredifferentialinnomographI(pBellows laden - pBellows unladen),here3.9bar(pointB).

– ConnectpointsA-BtoobtainpointCatthecross-pointwiththeidentifiedsuspension.

Ö You can now read the spring length L1(freehanging)andthespringstobeusedhere.

– In nomograph II, enter the spring length L1(pointD)andtheusedspringwithspringlengthL1(pointE).

108


– Afteryouhaveenteredtheaircushionpressurefortheunladenvehicle(pointF),connectpointsA-DandE-FtogetherandextendthempastDandEuptoreferencelines1and2.

Ö ConnecttheresultingpointsGandHwithoneanother. Atthecrossingpointwiththehelplines,youhavepointJ,atwhichyoucanreadtherequirednumber of spacers and the length of bolt L2. The values that are determined using the nomograph are guidelines and may have to be corrected.

Setting the LSVs

Before each adjustment of the screws and pressure p4, port 1 must be depressurised, otherwise the LSV cannot be adjusted to the required values due to the integrated statics.

Duetoproductiontolerancesandthehysteresis,afteradjustingthepressures(p1 and p41/42)itisalwayspracticabletoreadjusttheinputstartingfrom0barifnothingelseisspecified.

– AfteryouhaveinstalledtherightspringswithclampX(setdimensionL1)andthenumberofspacersNintheLSV,screwinscrew2(L2)untilyoucanfeelanoticeableresistance.

Setting the unladen end stop screwAfter charging p1withthecalculatedpressure(inthiscase6.5bar),theLSVmustoutputtheunladenbrakingpressure(inthiscase1.75±0.1bar)attheport2.

Iftheunladenbrakingpressureistoohigh,unscrewtheunladenendstopscrewW(L3);iftheunladenbraking pressure is too low, screw in the unladen end stop screw.

ii

UnscrewtheunladenendstopscrewWuptomax.23mm.

Setting the unladen braking pressureAfterchargingtheports41and42withtheunladenaircushionpressure+0.2bar(inthiscase0.4bar)andtheport1withthecalculatedpressure,theLSVmustoutputapressurethatis0.2barhigherthantheunladenbrakingpressurewithatoleranceof±0.1bar(inthiscase1.95±0.1bar).

– If the pressure is too low, unscrew screw 2; if the pressure is too high, screw in screw 2.

– Lock the screw 2.

Setting the braking pressure for the laden vehicleAfterchargingtheports41and42withthebellowspressurefortheladenvehicle-0.1bar(inthiscase4.0bar),theLSVmustoutputtheinputpressure-0.3barwithatoleranceof±0.2bar(inthiscase6.2±0.2bar).

Output pressure too low – DetermineΔp(pressuredifferentialbetweenthenominalvalueandactualvalue).

– Lowertheinputpressureto0bar.

– Lowerthebellowspressureto0barandincreasethevaluefortheunladenvehicle+0.2bar (inthiscase0.4bar).

– Unscrewthescrew2(Δp=0.1barcorrespondsto3mm).

– Unscrewthespringclampuntilthenominalvalue(inthiscase1.95±0.1bar)isattained.

– Repeat the test "Setting the braking pressure for the laden vehicle".

109


Output pressure too high – DetermineΔp.


– Lowerthebellowspressureto0barandincreasetothevaluefortheunladenvehicle+0.2bar (inthiscase0.4bar).

– Screwinthescrew2(Δp=0.1barcorrespondsto3mm).

– Screwinthespringclampuntilthenominalvalue(inthiscase1.95±0.1bar)isattained.


– Actuate all the test points again after setting the LSV.

– TightenthelocknutsonthescrewsWand2tothespecifiedtorque(8+2Nm).

– EnterthedataontheLSVplate(ordernumber8991446314)andfastenitontothevehicle.

Technical data

ORDER NUMBER 475 714 500 0 475 714 509 0 Max. operating pressure p1

10bar

Max. control ratio 8:1Max. control pressure p41/42

12 bar


-40°Cto+80°C

Weight 1.8 kg

110


Pressure diagrams

4757145000

4757145090

LEGENDp1 Input pressure p2 Outputpressure p41 = p42 Control

pressure

111


5.26.4 LSV trailer brake valve 475 715

Application

Static LSV with integrated trailer brake valve for air-suspension semitrailers with multiple axles without TrailerEBS.

Purpose

Controlofthetwo-linetrailerbrakingsystemswhenactuatingthebrakingsystemofthetowingvehicle.

Automatic control of braking force with the integrated LSV depending on the load status of the vehicle andthereforefromthecontrolpressureoftheair-suspensionbellows(air-bags).

Actuation of the automatic trailer braking with partial or total pressure drop in the supply line.

The LSV trailer brake valve is specially designed for air-suspension semitrailers with multiple axles.

Maintenance

– To test the LSVs, fasten a test hose to connection 43.

Ö Screwingonpressesthepiston(q)intothehousing,therebyinterruptingconnections41and42tothepistons(pando).Atthesametime,acompressedairconnectionfromconnection43tothe pistons is created. In this state, the LSV sets itself to a control position corresponding to the air pressure in the test hose.


– Fasten the LSV trailer brake valve onto the frame of the vehicle so that vent 3 faces downward.

– Makeconnections41and42withtheair-suspensionbellows(air-bags)ontherightandleft vehicle sides.

112



CONNECTIONS PORT THREADS1-2 Energysupply/

Energydischarge

1, 1-4

Energysupply 1 M16x1.5-12deep

1-2, 1/4 M 22x1.5 - 13 deep

2 Energydischarge

3 Venting 2 M16x1.5-12deep

(bottom)

2 M 22x1.5 - 13 deep

(side)41, 42 Control

connection43 Test connection 41,

42M12x1.5-10deep

113



@

@ @@





Description of the nomographs I and II for setting the LSV trailer brake valve 475 715 5XX 0

LEGENDi Controlratio

(pon-0.8)/(poff-0.5)

D Spacer 896 512 360 4 Compressionspring

(wireØ4mm)S2 Screw ΔpL Air cushion - pressure

differential;

pBellows laden - pBellows unladen

896 512 370 4 Compressionspring

(wireØ3.2mm)


114


LEGENDL1 Spring length H1 Reference line 1 N Number of spacers 896 512 360 4 Compression

springL2 Screw length H2 Reference line 2 i Controlratio

(pon-0.8)/(poff-0.5)

896 512 370 4 Compressionspring

L3 Unladenstopbolt(W)

p41/p42 Air cushion pressure "unladen"

115


Determining the compression springs and set length L1 and the number of spacers

REQUIRED ADJUSTMENT VALUESpon(p1)=6.5bar pBellows laden = 4.1 bar

pBellows unladen=0.2bar poff = p2 unladen = 1.75 bar

– Calculatethecontrolratio:

i=(pon-0.8)/(poff-0.5)=(6.5-0.8)/(1.75-0.5)=4.65

– EnterthecontrolratioinnomographsIandII(pointA).

– Inaddition,marktheaircushionpressuredifferentialinnomographI(pBellows laden - pBellows unladen),here3.9bar(pointB).

– ConnectpointsA-BtoobtainpointCatthecross-pointwiththeidentifiedsuspension.

Ö You can now read the spring length L1(freehanging)andthespringstobeusedhere.

– In nomograph II, enter the spring length L1(pointD)andtheusedspringwithspringlengthL1 (pointE).

– Afteryouhaveenteredtheair-suspensionbellowspressurefortheunladenvehicle(pointF),connectpointsA-DandE-FtogetherandextendthempastDandEuptohelp-lines1and2.

Ö ConnecttheresultingpointsG-Hwithoneanother. Atthecrossingpointwiththehelplines,youhavepointJ,atwhichyoucanreadtherequirednumber of spacers and the length of bolt L2. The values that are determined using the nomograph are guidelines and may have to be corrected.

Setting the LSVs

Before each adjustment to the bolts and pressure p41/p42, connection 4 must be depressurised, otherwise theLSVtrailerbrakevalve4757155XX0cannotbeadjustedtotherequiredvaluesduetotheintegrated statics.

Duetoproductiontolerancesandthehysteresis,afteradjustingthepressures(p1 and p41/42)itisalwayspracticabletoreadjusttheinputstartingfrom0barifnothingelseisspecified.

– AfteryouhaveinstalledtherightspringswithclampX(setdimensionL1)andthenumberofspacers N in the LSV, thread in bolt 2 until you can feel a noticeable resistance.

Setting the unladen end stop screwAfter charging p4withthecalculatedpressure(inthiscase,6.5bar),theLSVtrailerbrakevalvemustapplytheunladenbrakingpressure(inthiscase,1.75±0.1bar)atport2.

– Iftheunladenbrakingpressureistoohigh,unscrewtheunladenstopboltW(L3);iftheunladenbraking pressure is too low, screw the unladen stop bolt in

ii

UnscrewtheunladenendstopscrewWuptomax.23mm.

116


Setting the unladen braking pressureAfterchargingconnections41and42withtheunladenbellowspressure+0.2bar(inthiscase,0.4bar)and connection 4 with the calculated pressure, the LSV trailer brake valve must apply a pressure thatis0.2barhigherthantheunladenbrakingpressurewithatoleranceof±0.1bar(inthiscase1.95±0.1bar).

– If the pressure is too low, unscrew screw 2; if the pressure is too high, screw in screw 2.

– Lock the screw 2.

Setting the braking pressure for the laden vehicleAfterchargingtheports41and42withthebellowspressurefortheladenvehicle-0.1bar (inthiscase4.0bar),theLSVmustoutputtheinputpressure-0.3barwithatoleranceof±0.2bar (inthiscase6.2±0.2bar).

Output pressure too low – DetermineΔp(pressuredifferentialbetweenthenominalvalueandactualvalue).



– Screwoutbolt2(Δp=0.1bar=3mm).

– Unscrewthespringclampuntilthenominalvalue(inthiscase1.95±0.1bar)isattained.


Output pressure too high – DetermineΔp.



– Screwinbolt2(Δp=0.1bar=3mm).

– Screwinthespringclampuntilthenominalvalue(inthiscase1.95±0.1bar)isattained.


– Actuate all the test points again after setting the LSV.

– TightenthelocknutsonthescrewsWand2tothespecifiedtorque(8+2Nm).

– EnterthedataontheLSVplate(ordernumber8991446314)andfastenitontothevehicle.

Technical data

ORDER NUMBER 475 715 500 0 475 715 507 0 475 715 513 0 475 715 514 0Max. operating pressure p1/4 10barMax. control ratio 8:1Max. control pressure p41.42 12 barThermal range of application -40°Cto+80°CWeight 1.8 kg

117


Pressure diagrams

4757155000

4757155070

4757155130

118


4757155140

Automatic braking

LEGENDp2 Output

pressurep4 Input pressure p41 = p42 Control

pressure

119


5.26.5 Plates "Set values LSV " 899 144 63X 4ThevehicleistobeequippedaccordingtotherequiredLSVspecificationsconformingwithECGuideline71/320EWGAppendixIIAnnextoII/1.1.4.2Paragraph7andtheECEprovisionNo.13Appendix10Paragraph7.TherespectivesignscanbeobtainedfromWABCO(seefollowingfigures).ThesesignscorrespondwiththedraftforstandardsDIN74267ofSeptember1982FormCandD.Theyareprovidedinthreelanguagesandofferthecapabilityfortableentriesforaxleloadsandtheoutput pressures of the LSV.

ii

The pressures to be entered in the LSV plate must be measured immediately before and aftertheLSV,sothatitisnotinfluencedbythecharacteristicsofotherdevicesofthebrakingsystem. Intheconfigurationofthebrakingsystems,testconnectionsaretobedesignedaccordingtostandardISOstandard3583/1974beforeandaftertheLSVcontroller. Oncontrolconnection41or42frompneumaticallyhydraulicallyactuatedLSVs,aspecialtestconnection is required. It blocks the control pressure from the air-suspension bellows or the overflowcylinderswhenthetesthoseisconnected. When the trailer is empty, any load status can be simulated with the help of test apparatus 4350080000. With mechanically hinged LSVs, the required load status for checking the LSVs is achieved with a manual adjustment.

LSVplate8991446304

for mechanically controlled LSVs

LSVplate8991446314

for pneumatically or hydraulically controlled LSV

Automatisch - lastabhängige Bremskraftregeleinrichtung (ALB) für Typ:Load sensing device for type:Dispositif de correction automatique de freinage pour type:

Hinterachse . Rear axle . Essieu arriére

EingangsdruckInput pressurePression d´entrée

bar

Vorderachse . Front axle . Essieu avantFeder NrSpring NoRessort No

AchslastAxle loadCharge essieu


AusgangsdruckOutput pressurePression de sortie


Weg s am HebelStroke s at leverCourse s au levier

Weg s am HebelStroke s at leverCourse s au levier

kg kgbar mm bar mm

Ventile NrValves NoValves No

Feder NrSpring NoRessort NoVentile NrValves NoValves No

L S L= mm L S

L= mm

L= mm

Automatisch - lastabhängige Bremskraftregeleinrichtung (ALB) für Typ:Load sensing device for type:Dispositif de correction automatique de freinage pour type:

Hinterachse . Rear axle . Essieu arriére

Eingangsdruck . Input pressurePression d´entrée bar

Vorderachse . Front axle . Essieu avantVentile NrValves NoValves N°

Ventile NrValves NoValves N°



FederungsdruckSuspension pressurePression suspension

FederungsdruckSuspension pressurePression suspension



kg kgbar bar bar bar

WithtwoLSVswithdifferentinputpressure,bothpressuresaretobenotedontheLSVplate, e.g.6.5/5.7.

120

Load sensing valve (LSV) 475 71X Load-dependent control valve 475 800

Nomographswww www

@

@ @@

Nomographs


– ClickonProductcatalogueINFORM=>Productnumber.

– EnterthedesiredLSVnumberintothesearchfield.


– ClickthelinkPublications.

LSV NOMOGRAPHS4757100400 47571090234757120000 475710902347571350X0 47571390234757145XX0 4757149023475715XXX0 4757159023

121

Load-dependent control valve 475 800

5.27 Load-dependent control valve 475 800

4758003030

Application

Vehicles with leaf-spring suspension and trailing steering axle.

Purpose

Controlofthesteeringstabilisationonatrailingsteeringaxledependingonthespringdeflectionandthus on the load status of the vehicle.

Maintenance



– Install the load-dependent control valve vertically so that the vent 3 points downward.

– Fastentheload-dependentcontrolvalvewithtwoM8boltsontherespectiveflange.

122

Load-dependent control valve 475 800 Load-dependent control valve 475 800


CONNECTIONS PORT THREADS LEGEND1 Energysupply 3 Venting M 12x1.5 - 12 deep A Overstroke B Fully laden

position2 Energy

dischargeC Central

positionD Unladen

position

123

Load-dependent control valve 475 800

Diagram

LEGENDp1 Input pressure p2 Outputpressure -30° to 30° Lever travel

Determining lever length L

FordeterminingtheleverlengthL,thefollowingvaluesmustbeknown:

Springdeflectionf=...mm Outputpressure"unladen"p2 unladen =...barSupply pressure p1 = ... bar Outputpressure"laden"=p2 laden = ...bar

– FordeterminingscalepointA(outputpressurep2)subtractp2 unladen from p2 laden.

– ThensubtractthedeterminedpressuredifferenceΔp2 from the supply pressure p1.

Ö The resulting value p2isthestartingpointAforalinethatismadetopointB(scaleforspringdeflectionf). The extension of these lines cross the scale of lever length L, at which the lever length at pointCcanthenberead.

Examplef=40mm

p1 =7.0bar

p2 unladen = 1.8 bar

p2 laden = 5.5 bar

Δp2 =p2 laden–p2unladen= 5.5 - 1.8 = 3.7 bar

p2=p1-Δp2=7.0-3.7=3.3bar

Inthefollowingnomograph,alineismadefromscalepointA=3.3bartoscalepointB=40mm.ExtendingthislinecrossesthescaleforleverlengthLinpointCat75mm.

124

Load-dependent control valve 475 800 Tristop® Cylinder 925 XXX

LEGENDf Springdeflection L Lever length p2 Outputpressurefor

p1 = 7 bar

Technical data

ORDER NUMBER 475 800 301 0Max. operating pressure 8 barControlrange 0to7.2barPermissible medium AirThermal range of application -40°Cto+80°CWeight 1.1 kg

125

Tristop® Cylinder 925 XXX

5.28 Tristop® Cylinder 925 XXX

DDSBDrum brake

Drum brake DDSB

Disc brake

Disc brake

Application

Utilisationonatleastonevehicleaxle.

Purpose

Combinedspringbrake-diaphragmbrakechambers(Tristop®Cylinders)areusedtogeneratethebrake force for the wheel brakes. They consist of the diaphragm portion for the service braking system and the spring-loaded portion for the auxiliary and parking braking systems.

Installation instructions for Tristop® cylinders

The approval of the axle manufacturer is necessary for installing Tristop®cylinders.WABCOisavailablefor any enquiries regarding testing methods.

Mounting bracketToensureenduringbolttension,thefollowingpointsmustbeconsidered:

� Aflatmountingsurface(deviationofmaximum0.4mm)overabreadthofatleast146mmand aheightofatleast40mmaboveandbelowthefasteningboltsisnecessary.

� The mounting surface of the bracket is only to be primed and not painted.

� Directcontactisrequiredbetweenbracket/cylinderandcylinder/nut.

� Do not use reinforcement strips, intermediate plates, washers, spring lockwashers and other locking elements.

Installation – Install the Tristop®cylinderwithuptoa30°slantbetweenhorizontalupwardfacingandvertical

downward facing piston rod. Theopendrain/breatherholemustpointdownwards(maximumpermissibledeviation±30°).

ii

Install the Tristop®cylinderwithgaitersealwiththepistonrodatamaximumofa60°downward angle.

– Sealadditionaldrainholes(exceptionTSLcylinder!).

– Seal the opening for the release screw. The bleed line between the service brake part and the spring brake part must run in the area of the upper half of the Tristop® cylinder. Themaximumpermitteddisplacementofthepistonrodis3°onallsides.

126

Tristop® Cylinder 925 XXX Tristop® Cylinder 925 XXX

LEGENDA Drain hole Z Permissible

installation position * 0to-60°usingTristop® cylinder with gaiter

FasteningFastening the Tristop®cylinderrequirestheuseofnutsM16x1.5–strengthclass8–DINEN28673,ISO8673(inaccessoriespack,WABCONo.4239035322).

– Thread on both nuts by hand until the Tristop® cylinder makes full contact.

– Tightenthenutstoapproximately120Nm(e.g.withanimpactwrench).

– Tightenthenutsto210Nm(tolerance-30Nm)usingatorquewrench. Increase the tightening torque appropriately when using self-locking nuts.

– Checkthetighteningtorqueof210Nminaccordancewiththemaintenanceintervalsoftheaxlemanufacturer.

Steering axle specifics

When installing Tristop® cylinders on steering axles, ask the axle manufacturer about the respective installation situation.

ReplacementWhen replacing a brake chamber, check the bracket for any damage and replace according to the axle manufacturer’s recommendations if necessary.

Installing a larger cylinder than type 30/30Types36/36and36/30arenottobemountedusinghorizontallypositionedfasteningbolts.Inthiscase,averticalpositionwithadeviationof±30°ispermitted.

General WABCOTristop® cylinders are delivered with the springs under tension. Release the springs before commissioning the vehicle. WiththeTSLtypes,fastenthereleasescrewintheholeprovidedontheside.Closethehole,onthecover with the cap attached to the device.

127


Installation instructions for Tristop® cylinders (disc brake)

Installation – Install the Tristop®cylinderhorizontally. Permissibledeviation:10°withpushrodshowingupwardand30°showingdownwards. Theopendrain/breatherholemustpointdownwards(maximumpermissibledeviation±30°).

– Remove the lower plastic plug. The connecting line between the service brake part and the spring brake part must run in the area of the upper half of the Tristop® cylinder.

FasteningFastening the Tristop®cylinderrequiresusingnutsM16x1.5–Strengthclass8–DIN934 (WABCONo.8103040314).

– Thread on both nuts by hand until the Tristop® cylinder makes full contact. Make sure that the piston rod goes into the calotte of the brake lever. Makesurethattheflangesurfacesandsealingsurfacesofthecylinderandthediscbrakeareclean and undamaged. Make sure that the gaiters are not damaged and are seated properly together with the back-up ring.

– Tightenbothnutstoapproximately120Nm(e.g.withanimpactwrench).

– Tightenbothnutsto210Nm(tolerance-30Nm)usingatorquewrench.

– Movethereleasebolttodrivepositionafterfastening(securewith25+20Nm).

Install dimensions - Double diaphragm spring brake actuator for S-cam drum brakewww www

@

@ @@

Outlinedrawingwithinstalldimensions


– ClickonProductcatalogueINFORM=>Productnumber.

– Entertheordernumberofthedesireddoublediaphragmspringbrakeactuatorintothesearchfield.



128


Technical Data - Double diaphragm spring brake actuator for S-cam drum brake

OR

DER

NU

MB

ER

TYPE

MA

X. S

TRO

KE

[mm

] D

IAPH

RA

GM

CYL

IND

ER

AN

D S

PRIN

G A

CTU

ATO

R

CYL

IND

ER

DIS

PLA

CEM

ENT O

F PU

SH

RO

D IN

AN

Y D

IREC

TIO

N

VOLU

ME-

STR

OK

E O

F TH

E B

RA

KE

CH

AM

BER

AT

2/3

STR

OK

E [li

tres

]

VOLU

ME

STR

OK

E O

F TH

E SP

RIN

G C

HA

MB

ER

CYL

IND

ER [l

itres

]

MA

X. O

PER

ATIN

G

PRES

SUR

E [b

ar]

THER

MA

L R

AN

GE

OF

APP

LIC

ATIO

N

INST

ALL

ATIO

N

DIM

ENSI

ON

S D

[mm

]

OU

TPU

T FO

RC

E O

F TH

E SP

RIN

G C

HA

MB

ER A

T ST

RO

KE

30 m

m [k

N]

WEI

GH

T [k

g]

9253751000 20/30 75 6° 0.9 2.12

8.5

-40°Cto+80°C

149

6.6±0.3

9.29253761000 24/30 75 6° 1.9 2.12 162 9.7 9253761010 24/30 75 6° 1.09 2.12 162 9.79253761030 24/30 75 6° 1.09 2.12 162 9.99253761060 24/30 75 6° 1.16 2.12 162 10.39253761070 24/30 75 6° 1.09 2.12 162 9.99253761100 24/30 75 6° 1.09 2.12 162 9.99253762000 24/30 64 6° 0.9 1.92 161 9.39253771000 30/30 75 6° 1.32 2.12 182 109253771010 30/30 75 6° 1.32 2.12 182 109253771020 30/30 75 6° 1.32 2.12 182 109253771030 30/30 75 6° 1.32 2.12 182 10.29253771050 30/30 75 6° 1.32 2.12 182 10.2

4239035352Yokeendwithoutfasteningnut/4239035322Yokeendwithnut

Pressure diagrams - Double diaphragm spring brake actuator for S-cam drum brake

LEGENDa Outputforceofthespringchamber,releasepressure

pe=4.6±0.3barF Force

b Outputforceoftheservicebrakepartatpe=6.5bar H Strokec Return-spring force of the service brake part

129


Technical data – Tristop® Cylinder (cam)

OR

DER

NU

MB

ER

TYPE

MA

X. S

TRO

KE

[mm

] D

IAPH

RA

GM

CYL

IND

ER

AN

D S

PRIN

G A

CTU

ATO

R

CYL

IND

ER

REL

EASE

TO

RQ

UE

[Nm

] REL

EASE

DEV

ICE

TIG

HTE

NIN

G T

OR

QU

E [N

m]

DIS

PLA

CEM

ENT

OF

PUSH

R

OD

IN A

NY

DIR

ECTI

ON

VOLU

ME-

STR

OK

E O

F TH

E B

RA

KE

CH

AM

BER

AT

2/3

STR

OK

E [li

tres

]

VOLU

ME

STR

OK

E O

F TH

E SP

RIN

G C

HA

MB

ER

CYL

IND

ER [l

itres

]

MA

X. O

PER

ATIN

G

PRES

SUR

E

THER

MA

L R

AN

GE

OF

APP

LIC

ATIO

N

OU

TPU

T FO

RC

E O

F TH

E SP

RIN

G C

HA

MB

ER A

T ST

RO

KE

30 m

m [k

N]

WEI

GH

T [k

g]

9254940410 16/24 65 15 +20 25 +20 3° 1.13 1.8

8.5

bar

-40°Cto+80°C

7.9 11.59254901050 20/24 65 15 +20 70 3° 0.8 1.4 8±0.4 9.89254911140 24/24 65 15 +20 70 3° 0.8 1.4 8±0.4 9.89254911110 24/30 65 15 +20 70 3° 0.8 1.4 10.2±0.4 9.99254922040* 30/24 65 15 +20 70 3° 1.13 1.4 8±0.4 9.29254922080 30/30 65 15 +20 70 3° 1.13 1.8 10.2±0.4 11.59254923000** 30/30 65 15 +20 70 3° 1.13 1.8 10.2±0.4 9.9

LEGEND* Installationposition+90°/-30° ** Installationposition+50°/-10°

Pressure diagrams – Tristop® Cylinder (cam)

LEGENDa Outputforceofthespringchamber,releasepressurepe=4.6±0.3bar F Forceb Outputforceoftheservicebrakepartatpe=6.5bar H Strokec Return-spring force of the service brake part

130


Technical data

Order number Type Max. stroke [mm]9253840010 16/24 579253801010 20/24 64

Max. operating pressure 8.5 bar Volume-stroke of the brake chamber at2/3stroke[litres]

0.51

Volume stroke of the spring chamber cylinder [litres]

0.754

Min. nominal diameter Ø 11.5Thermal range of application -40°Cto+80°CWeight 6.6kg

Installation dimensions for 925 464 500 0 – Tristop® cylinder (disc brake)

PORT THREADS LEGENDM16x1.5 A In mounted

position lower breather hole ±30°

B Release position as supplied

C Ball D Stroke E Permissible installation position

131


TYPE Installation dimensions [mm]L1 L2 L3 L4 L5 L6 L7 L8 D1 D2 D3 R1 α β

16/16 320 252 237 227 64 90 96 90 146 167 158.5 101 45° 90°16/24 318 253 237 227 64 92 96 90 146 167 173.5 101 45° 90°18/24 328 258 243 233 65 96 99 90 153 175 173.5 106 36° 90°20/24* 328 258 243 233 65 96 99 90 153 175 173.5 106 45° 90°20/24** 320 253 238 229 65 92 98 90 153 175 173.5 106 90° 110°

LEGEND* 9254809600 ** 9254600320

Technical data – Tristop® cylinder (disc brake)

ORDER NUMBER

TYPE

MA

X. S

TRO

KE

[mm

]

VOLU

ME-

STR

OK

E O

F TH

E B

RA

KE

CH

AM

BER

AT

2/3

STR

OK

E [li

tres

]

VOLU

ME

STR

OK

E O

F TH

E SP

RIN

G C

HA

MB

ER

CYL

IND

ER [l

itres

]

MA

X. O

PER

ATIN

G

PRES

SUR

E SE

RVI

CE

BR

AK

E SY

STEM

SPR

ING

C

HA

MB

ER C

YLIN

DER

THER

MA

L R

AN

GE

OF

APP

LIC

ATIO

N

WEI

GH

T [k

g]

α = RIGHT β = LEFT

α = LEFT β = RIGHT

UNIVERSAL: CONNECTIONS

TOP β = LEFT

9254644500 9254644510 9254644520 16/16 57 0.54 1.28.

5 ba

r

-40°Cto+80°C

7.09254644610

α=90°, β=70°

16/16 57 0.54 1.2 7.0

9254645000 9254645010 16/24 57 0.54 1.4 8.09254635000 9254635010 9254635020 18/24 64 0.8 1.4 9.19254601000 9254601010 9254809600 20/24 64 0.8 1.4 9.2

9254600320 20/24 57 0.6 1.4 8.09254610500 9254610510 9254610520 24/24 64 0.8 1.4 9.2

132

Tristop® Cylinder 925 XXX Drain valve 934 300 / 934 301

Pressure diagrams – Tristop® cylinder (disc brake)

LEGENDH Stroke F Force

133

Drain valve 934 300 / 934 301

5.29 Drain valve 934 300 / 934 301

Drain valve

934300

Automatic drain valve

934301

Application

Ondrainandpressurereservoirs.

Purpose

Protection of the compressed-air equipment from ingress of condensate by means of automatic or manual draining of the air reservoir.

Maintenance

Drain valve 934 300 – If the valve does not close or open upon actuation, it must either be cleaned or replaced.

Automatic drain valve 934 301Special maintenance that extends beyond the legally stipulated inspections is not required.


Drain valve 934 300 – EquipthedrainvalvewithasealringA22x27DIN7603Al,ordernumber8114010804andthreaditintothebaseconnectionfortheairreservoir(tighteningtorque=45Nm). Theactuatingpinisprovidedwithaholeforattachingthepull-wire(9343000030withactuatingring).

– Do not mount any devices under the drain valve to ensure that the condensation will not become contaminated when draining.

Automatic drain valve 934 301Special maintenance that extends beyond the legally stipulated inspections is not required.

134

Drain valve 934 300 / 934 301 Drain valve 934 300 / 934 301

Install dimensions for 934 300

Install dimensions for 934 301

135

Drain valve 934 300 / 934 301

Technical data

ORDER NUMBER 934 300 001 0 934 300 002 0 934 300 003 0Max. operating pressure 22 bar 20barVersion(seeFig."InstallationDimensions")

1) 2)

ConnectingthreadG(seeFig."InstallationDimensions")

M 22x1.5 R1/2"DIN259

M 22x1.5

Permissible media Air, water, mineral oilThermal range of application

-40°Cto+80°C

Correspondstostandard B DIN 74 292 – CDIN74292Material BrassWeight 0.05kg 0.06kg 0.05kg

ORDER NUMBER 934 301 000 0Max. opening pressure 20barConnectingthreadG(seeFig."InstallationDimensions")

M 22x1.5

Permissible media Air, water, mineral oil Thermal range of application -40°Cto+80°CWeight 0.46kg

136

Air reservoir 950 XXX Air reservoir 950 XXX

5.30 Air reservoir 950 XXX

Application

For all vehicles with compressed air braking systems.

Purpose

Storage of the compressed air delivered from the compressor.

Design

The reservoir consists of the cylindrical portion in the centre with welded-in arched bases and screw necks for connecting pipes.

A further port is located at the centre section where a draining facility can be attached for regular draining of condensation water.

The material for the plates is R St 37-2. The inner wall of the container is protected against corrosion by a synthetic resin paint. The outside surface is primed with a synthetic resin.

A plate is located at one end, indicating the name and address of the supplier, the supplier's part number, the year of manufacture, the maximum operating pressure [bar], the capacity [litres], the serial number,testmark,thevolumexdiameterand–forsometypesonly–DIN74281.

Maintenance

– Drain the air reservoir daily.

ii

We recommend using drain valves which are available for both manual and automatic actuation.

137

Air reservoir 950 XXX


– Attach the clamp bands so that the connecting seams do not touch the base and the reservoir is not subjected to any tension that could jeopardise operational safety. The fastening is done using straps or the brackets of the reservoir. Put insulation strips between the reservoir and the straps if necessary.

– Installthereservoirhorizontallyorvertically. Make sure that one drain pipe is located at the lowest point of the reservoir. Makesurethatanycondensationcanbeemptiedand/orthecollectionofcondensationisprevented.

Ö Thereservoirplatemustbeeasilylegibleinthespecifiedinstallationpositionwhenthereservoiris installed.

ii

No heat treatment or welding is to be done on the walls of the reservoir that are under pressure.


PORT THREADSM 22x1.5 - 12 deep

138

Air reservoir 950 XXX Coupling head 952 20X / 452 XXX

Technical data

ORDER NUMBER CONTENT [litres] LENGTH L [mm] DIAMETER D [mm] MAX. OPERATING PRESSURE [bar]

WEIGHT [kg] ±10 %

9504050010 4.5 185 206 15.5 3.09504100040 10 368 206 15.5 4.79504200030 20 691 206 15.5 8.09505200030 20 495 246 15.5 7.29505300020 30 709 246 15.5 10.09505370010 37 862 246 15.5 11.99505400010 40 927 246 15.5 12.79507400020 40 758 276 14.5 11.59505600020 60 1365 246 15.5 18.09507600020 60 1108 276 14.5 16.29500600030 60 893 310 12.5 15.29500600040 60 580 396 12.5 16.39500800020 80 750 396 12.5 20.59501000020 100 915 396 12.5 24.5

CLAMPING BAND CYLINDER Ø ORDER NUMBER206 4519992062246 4519992462276 4519992762310 4519993102396 4519993962

Rubberspacer:4519999990(50m)

139

Coupling head 952 20X / 452 XXX

5.31 Coupling head 952 20X / 452 XXX

5.31.1 Coupling head 952 20X

9522000210

for the supply line A1

with red closing cap

9522000220

for brake line A2

with yellow closing cap

Application

In the supply- and brake-line between the towing vehicle and the trailer.

Purpose

Connectthetwolineswithcross-couplingsafeguard.

ThehosecouplingsconformtotheISO1728standard.

Maintenance


ii

Ifautomatichosecouplingsareused,theshut-offcocknormallyrequiredisnotrequired. Whenever the trailer parts from its towing vehicle, the lines will always rupture. The hose couplings do not become disconnected.

ii

Afterunhitchingthevehicle,theplasticcover(redoryellow)mustbescrewedontothecoupling head opening to prevent dirt from entering.

Test

For leakages only.

140

Coupling head 952 20X / 452 XXX Coupling head 952 20X / 452 XXX

Technical data

ORDER NUMBER 952 200 021 0 952 200 022 0Design For the supply line A1

with red closing cover and an axial safeguard against cross-coupling

For brake line A2 with yellow closing cover

and a lateral safeguard against cross-coupling

Method of utilisation Semitrailer Truck

TractorMax. operating pressure

10bar


-40°Cto+80°C


Dummycoupling:Ordernumber4524020000

Overview

ii

Couplingheadsoftheolder452200seriescanbeconnectedtocouplingheadsofthe952200serieswithoutanyproblem.

COUPLING HEADSTOWING VEHICLE TRAILER THREAD COLOUR COMMENT

For Swiss type braking systems

4523030310 4522030310 M 22x1.5 red Supply line4523030320 4522030320 M 22x1.5 yellow Brake line

Dual line braking system

4522000000 M 22x1.5 – without closing cover4522000040 M 22x1.5 black Black closing cover

4522002110 4522000110 M 22x1.5 red Supply9522002210 9522000210 M16x1.54522002120 4522000120 M 22x1.5 yellow Brake line9522002220 9522000220 M16x1.5

9522000400 M16x1.5with test port

yellow Brake line

9522002100 2xM16x1.5 red Supply

Duo-Matic

4528020090 4528040120 M22x1.5/M16x1.5 Towingvehicle/Trailer

4528050040 4528030050 M22x1.5/M16x1.5 Tractorunit/semitrailer

4528020070 4528030040 M22x1.5/M16x1.5 Tractorunit/semitrailer(withquick-connect)

141


Usingdoubledpipe8931001384,thecouplingheadwithanM22x1.5threadcanbereplacedwithaheadwithanM16x1.5thread.

8931001384


142

Coupling head 952 20X / 452 XXX Coupling head 952 20X / 452 XXX


ThehosecouplingsmustbeinstalledaccordingtoISO1728,seethefollowingdrawings.

Tractor trailer combination Semitrailer tractor

LEGEND1 Free space for

coupling2 Supply line 3 Brake line 4 Max. deviation from

horizontal


Supplyline(red)

Controlline(yellow)

143


5.31.2 Coupling head with integrated line filters 952 201

Application

In the supply- and brake-line between the towing vehicle and the trailer.

Purpose

When making the coupling, the hose couplings on the towing vehicle and the trailer are connected with one another. This occurs by twisting and interlocking the opposing guides at the same time.

Anadditionallinefilterisnotrequired.

ii

Combiningimportantfunctionsinasingleproduct. Benefits:feweraccessories,lowerspacerequirements,fewerparts,quickandeasyinstallation.


Brake line A1 Supply line A2

PORT THREADS LEGENDZ=M16x1.5 1) Yellow cap 3) Interchange catch

2) Red cap

144

Coupling head 952 20X / 452 XXX Double release valve 963 001 / Trailer release valve 963 006

ORDER NUMBER DESIGN VARIANT MAX. OPERATING PRESSURE

THERMAL RANGE OF APPLICATION

SUPPLY LINE (RED CAP)

BRAKE LINE (YELLOW CAP)

9522010010 X

8.5 bar -40°Cto +80°C

9522010030 X

9522010020 X

9522010040 X

9522010070 X9522010080 X

9522010110 X9522010120 X9522010130 X

9522010140 X Onlyouterthread9522010150 X9522010160 X No thread9522010170 X

145

Double release valve 963 001 / Trailer release valve 963 006

5.32 Double release valve 963 001 / Trailer release valve 963 006

9630010120

9630010130

9630010510

9630010530

9630060010

9630060030

9630060050

Application

For trailers

Purpose

Release the braking system to move the semitrailer when not coupled.

146

Double release valve 963 001 / Trailer release valve 963 006 Double release valve 963 001 / Trailer release valve 963 006

Technical data

ORDER NUMBER 963 001 012 0 963 001 013 0 963 006 001 0 963 006 003 0 963 006 005 0 963 001 051 0

963 001 053 0


8.5 bar

Min. nominal diameter

1-1 => 2

Ø 8 Ø 8 -

Min. nominal diameter

1-2 => 2

Ø6 Ø6 -

Port threads M16x1.5-13 deep

M 22x1.5 - 13 deep

Installation dimensions L1

51 mm 54.5 mm


104.5mm 107mm


36.7mm 39 mm

Colouroftheactuation button

black black red green Twobuttons:

black/redPermissible medium

Air


-40°Cto+80°C

Weight 0.13kg 0.21kg 0.15kg 0.73kg

ii

Thetrailerreleasevalve9630060030hasaredactuationbutton,inconnection1-1aventvalve and is suitable for Tristop®cylinderslikethedoublereleasevalve9630010510. Thetrailerreleasevalve9630060050isidenticaltothe9630060030butwithagreenactuation button for lifting axles.


� Mountthetrailerreleasevalves9630060010,9630060030and9630060050aswellasthedoublereleasevalves9630010510and9630010530easilyaccessibleinthefrontareaofthetrailer.

� Flangethetrailerreleasevalve9630010120and9630010130directlyontothetrailerbrakevalve.

– Install the trailer release valve vertically so that the actuation button faces downward. Permissibleinstallationposition:±90°

– Fasten the trailer release valve with two M8 bolts.

147




CONNECTIONS LEGEND1-1 Energysupply 1-2 Energysupply

(Reservoir)

A Driving position

D Black

actuating knob2 Energy

discharge3 Venting B Parking

positionE Red

actuating knob21 Predominance

(trailerbrakevalve)

22 Energydischarge

(Springchamber cylinder)

C Release position

X View

148

Double release valve 963 001 / Trailer release valve 963 006 Double release valve 963 001 / Trailer release valve 963 006


LEGEND1-1 Energysupply 1-2 Energysupply

(Reservoir)

2 Energydischarge

149


Plates with parking and driving symbols

8992006954(suppliedunassembled)

Fordoublereleasevalves9630010510and9630010520

Maintenance


150

Shut-off valve 964 001 Shut-off valve 964 001

5.33 Shut-off valve 964 001

Application

Vehicles with special equipment for dropping swap-trailers.

Purpose

Stroke limit on vehicles with lift equipment.

Maintenance



– Installtheshut-offvalvesothatthefasteningboltsareonlystressedinthelongitudinaldirection.

151

Shut-off valve 964 001


152

Shut-off valve 964 001 Shut-off valve 964 001


Drawbartrailer(liftingandlowering)

Semitrailer(Liftingandlowering)

LEGENDA Supply, from the

service brake systemB Air suspension bellows C Non-return valve D LSV controller

Technical data

ORDER NUMBER 964 001 002 0 Max. operating pressure 12 barNominal diameter 7 mmPermissible medium AirThermal range of application -40°Cto+80°CWeight 0.4kg

153

Shut-off valve 964 001

Diagram

LEGENDF Actuating force s Tappet travel

154

Trailer brake valve with adjustable predominance 971 002 Trailer brake valve with adjustable predominance 971 002

5.34 Trailer brake valve with adjustable predominance 971 002

Application

Vehicleswithconventionaltwo-lienbrakecontrol(notTrailerEBS).

Purpose

To control the dual-line air braking system of the trailer.

Maintenance

– Checkthestatusofthefiltersinconnection4and1.

Ö Replacethefilterifnecessary.


– Install the trailer brake valve vertically so that vent 3 faces downward.

– FastenthetrailerbrakevalvewithtwoM10screws.

155

Trailer brake valve with adjustable predominance 971 002


LEGEND1 Energysupply 1-2 Energysupplyor

discharge

(Reservoir)

4 Controlconnection M 22x1.5 - 15 deep

2 Energydischarge 3 Venting

156


Installation dimensions for 971 002 531 0: Combination trailer brake valve 971 002 150 0 with release valve 963 001 012 0


discharge

(Reservoir)

4 Controlconnection

M 22x1.5 - 15 deep

2 Energydischarge 3 Venting 1 M16x1.5-13deep

WHEN NOT IN USE, SECOND PORT 2 MUST BE CLOSED USING

ORDER NUMBER

Screw plug M 22x1.5 8930100704RingsealA22x27DIN7603-Al 8114010804

157


Installation dimensions for 971 002 570 0: Combination trailer brake valve 971 002 150 0 with load-sensing valve 475 604 011 0


discharge

(Reservoir)

4 Controlconnection M 22x1.5 - 15 deep

2 Energydischarge 3 Venting

SYMBOLSRelease position

Unladen

Half laden

Fully laden

158


Installation dimensions 971 002 300 0

LEGEND1-2 Energysupply

or discharge (supplyreservoir)

1 Energysupply 2 Energydischarge

3 Venting 4 Controlconnection

Technical data

ORDER NUMBER 971 002 150 0 971 002 300 0 971 002 301 0Max. operating pressure 10bar 8.5 barFactory setting of predominance

0bar without

Dead volume 0.205litres –Thermal range of application

-40°Cto+80°C

Port 4 – M16x1.5Weight 1.8 kg 1.4 kg

159


Diagram

Automatic braking Service brake application

LEGENDp1 Input pressure p2 Output

pressurep4 Control

pressureA Setting range B Initialfill

160


5.34.1 Trailer brake valve 971 002 152 0

Application

Application especially in long semitrailers with multiple axles.

Purpose

Controlofthetwo-linesemitrailerbrakingsystemswhenactuatingthebrakingsystemofthetowingvehicle. Triggering of the automatic semitrailer braking with partial or total pressure drop in the supply line.

Maintenance

– Checkthestatusofthefiltersinconnection4and1.

Ö Replacethefilterifnecessary.


– Install the trailer brake valve vertically so that vent 3 faces downward.

– FastenthetrailerbrakevalvewithtwoM10screws. The connection from connection 1-2 to the supply reservoir should be kept as short as possible and have the largest cross-section possible.

– Install a trailer release valve in the supply line between the coupling head and the trailer brake valve.

– Install the LSV controller in the brake line before connection 4 of the trailer brake valve.

ii

On3-axlesemitrailersconnectthefourdown-facingconnections2(withthreadM16x1.5)directlywiththefourbrakecylindersonthe1stand2ndaxleswithhoses.Connectthe5thconnection2(threadM22x1.5)viaacommonlineandthenviaseparatedhoseswiththecylinders on the third axle.

On2-axlesemitrailers,connecttheconnection2withthreadM22x1.5usingascrewplug.

On1-axlesemitrailers,youmustcloseofftwootherconnection2withscrewplugsM16x1.5.

161



LEGEND1-2 Energysupplyor

discharge

(Reservoir)

1 Energysupply 2 Energydischarge

3 Venting 4 Controlconnection

162

Trailer brake valve with adjustable predominance 971 002 Park release emergency valve (PREV) 971 002

Pressure diagrams

Automatic braking Service brake application

LEGENDp1 Input pressure p2 Output

pressurep4 Control

pressureA Setting range B Initialfill

Technical data

ORDER NUMBER 971 002 152 0Max. operating pressure 10barDead volume 0.205litresThermal range of application -40°Cto+80°CWeight 1.66kg

163

Park release emergency valve (PREV) 971 002

5.35 Park release emergency valve (PREV) 971 002

Application

VehiclewithTrailerEBSversionDandE.

Purpose

The park release emergency valve replaces the trailer brake valve and the twin release valve, used tillnowinthetrailerbrakingsystemsoftheEBSDgeneration.Thisvalvesimplifiesthetrailerbrakingsystem by the elimination of one device and realises the functions typically for the trailer braking valve, astear-offfunctionorpressurerestraintwhenthe(semi-)trailerhasbeenunhitched.

Installation diagram – Trailer EBS E

2S/2Msystem

LEGEND1 PowersupplyviaISO

76382 Brake line 3 Supply line

4 Stop light supply via ISO1185(optional)

5 TrailerEBSEmodulator 6 Park release emergency valve (PREV)

7 Overloadprotectionvalve

8 Tank 9 Sensors

164

Park release emergency valve (PREV) 971 002 Park release emergency valve (PREV) 971 002


LEGENDA Driving position B Parking position C Release position

Technical data

ORDER NUMBER 971 002 900 0 971 002 902 0 971 002 910 0 971 002 911 0 971 002 912 0 971 002 913 0Operatingpressure p1-1 8.5 bar

Max. permissible operating pressure (brief)

p1-110bar

Installation restrictions Maximumdeviationofthedevicefromthevertical±15°

165

Park release emergency valve (PREV) 971 002

ORDER NUMBER 971 002 900 0 971 002 902 0 971 002 910 0 971 002 911 0 971 002 912 0 971 002 913 0Thermal range of application -40°Cto+65°C

Weight 1.6kg 1.8 kg 1.9 kg 1.8 kgQuickfitconnections no yes

Plate with parking and driving symbols

9710021034(suppliedunassembled)

Pressure diagrams

LEGENDp1-1 Input pressure A Spring chamber

cylinder 22B Modulator 21

p1-2 Connection C Automatic braking D Initialfill

p21; p21/22 Outputpressure

166

Relay valve 973 0XX Relay valve 973 0XX

5.36 Relay valve 973 0XX

9730010100

9730010200

9730110000

Application

With especially large brake cylinder volumes

Purpose

To rapidly increase or decrease the pressure of compressed air equipment and to shorten the response and pressure build-up times in air braking systems

Maintenance



– Install the relay valve so that vent 3 points downward.

– Fasten the relay valve with either two of the four housing fastening bolts M8.

167

Relay valve 973 0XX



discharge3 Venting 4 Control

connection

168



Permissibleinstallationposition:±90°


discharge3 Venting 4 Control

connection

Technical data

ORDER NUMBER 973 001 010 0 973 001 020 0 973 011 000 0Max. supply pressure 22 bar 13 barOutputpressurep2 8 bar 10barControlpressurep4 8 bar

(Max.operatingpressure:10bar)

8 bar 10bar

Port threadsM 22x1.5 - 14 deep

1 = M 22x1.5 - 14 deep

2,4=M16x1.5-14deep

1, 2 = M 22x1.5 - 13 deep

4=M16x1.5-12deepThermal range of application -40°Cto+80°C

Weight 1.1 kg 0.62kg

169

Relay valve 973 0XX

Pressure diagrams

9730010100

9730010200

9730110000

LEGENDp2 Outputpressure p4 Controlpressure

5.36.1 Overload protection valve 973 011 201 0

Application

Especiallywithdrum-brakevehicles

Purpose

Fortheprotectionofthewheelbrakefromoverload(addedforce)whenserviceandparkingbrakeareactuated simultaneously,

Quickchargeandventingofthespringchamberdiaphragmcylinders(Tristop®cylinders).

TrailerEBSEwithPEM:Theoverloadrelayvalveisalreadyintegratedinthepneumaticextensionmodule(PEM).

170



Permissibleinstallationposition:±90°

Technical data

ORDER NUMBER 973 011 201 0Max. supply pressure 12 barMax. control pressure p41/42 10barPort threads 1=M22x1,5(Mmax. =53Nm)

M16x1.5(Mmax.=34Nm)

Thermal range of application -40°Cto+80°C

171

Relay valve 973 0XX

Pressure diagram 973 011 201 0

LEGENDp21 Outputpressure p41/42 Controlpressure

172

Proportioning pressure regulator 975 001 / 975 002 Proportioning pressure regulator 975 001 / 975 002

5.37 Proportioning pressure regulator 975 001 / 975 002

5.37.1 Proportioning pressure regulator with straight characteristic curve 975 001

Application

Fortrailersthatrequireadaptingtodifferentbrakepadwearondifferentaxles.

Purpose

To reduce the braking force of the axle to be adapted during partial brake applications and rapid exhausting of brake cylinders.

Trailers being operated in mountainous regions and frequently covering downhill journeys always show increased wear on the brake linings of the front wheels because the arrangement of the larger front wheel brake cylinders required for stopping will cause excess braking on the front axle. By using the pressure ratio valve, the braking force on the front axle is reduced to the extent that both axles are braked evenly; this does not, however, in any way impair the brake force during full braking.

Maintenance



– Mount the adapter valve half way between the two brake cylinders of the axle to be adapted.

– Install the proportioning pressure regulator so that vent 3 points downward.

– Fasten the pressure ratio valve with two M8 screws.

173

Proportioning pressure regulator 975 001 / 975 002


CONNECTIONS PORT THREADS1 Energysupply 2 Energy

discharge3 Venting M 22x1.5 - 15 deep

174

Proportioning pressure regulator 975 001 / 975 002 Proportioning pressure regulator 975 001 / 975 002

Installation dimensions for 975 001 500 0: Combination pressure ratio valve 975 001 XXX 0 with test valve 463 703 XXX 0

CONNECTIONS PORT THREADS1 Energysupply 2 Energy

discharge3 Venting M 22x1.5 - 15 deep

175

Proportioning pressure regulator 975 001 / 975 002

Technical data

ORDER NUMBER 975 001 000 0 975 001 001 0 975 001 002 0 975 001 500 0Max. operating pressure

10bar

Setting range 0.3to1.1barTo be set at 0.7±0.1bar 1±0.1bar 0.5±0.1bar 0.7±0.1barNominal diameter 12 mmPermissible medium AirThermal range of application

-40°Cto+80°C


Pressure diagrams

9750010000

9750015000

9750010010 9750010020

176

Device description Device description

5.37.2 Proportioning pressure regulator with drop characteristic curve 975 002

Application

For trailers, the brake force distribution of which must be adapted on one axle.

Purpose

To reduce the braking force of the axle to be adapted during partial brake applications and rapid exhausting of brake cylinders.

Maintenance



– Mount the adapter valve half way between the two brake cylinders of the axle to be adapted.

– Install the proportioning pressure regulator so that vent 3 points downward.

– Fasten the proportioning pressure regulator with the set screw on the side and an M8 nut.

177

Device description


Technical data

ORDER NUMBER 975 002 017 0Max. operating pressure 10barNominal diameter 7.5 mmL1(seeFig."InstallationDimensions") 25 mmPermissible medium AirThermal range of application -40°Cto+80°CWeight 0.60kg

Diagram

Notes

178

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ZF Friedrichshafen AGZF is a global technology company and supplies systems for passenger cars, commercial vehicles and industrial technology, enabling the next generation of mobility. ZF allows vehicles to see, think and act. In the four technologydomainsVehicleMotionControl,IntegratedSafety,AutomatedDriving,andElectricMobility,ZFofferscomprehensivesolutionsforestablishedvehiclemanufacturersandnewlyemergingtransportandmobilityserviceproviders.ZFelectrifiesdifferentkindsofvehicles.Withitsproducts,thecompanycontributestoreducingemissions and protecting the climate.

ZF,whichacquiredWABCOHoldingsInc.onMay29,2020,nowhas162,000employeesworldwidewithapproximately260locationsin41countries.In2019,thetwothen-independentcompaniesachievedsalesof€36.5billion(ZF)and$3.4billion(WABCO).

WiththeintegrationofWABCO,theleadingglobalsupplierofbrakingcontrolsystemsandotheradvancedtechnologiesthatimprovethesafety,efficiencyandconnectivityofcommercialvehiclesZFwillcreateanewlevelof capability to pioneer the next generation of solutions and services for original equipment manufacturers and fleetsglobally.WABCO,withalmost12,000peoplein40locationsworldwide,willnowoperateundertheZFbrandasitsnewCommercialVehicleControlSystemsdivision.

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PNEUMATIC BRAKE EQUIPMENT FOR TRAILER VEHICLES