Maintenance guide Haldex immediate response (PR Plus)
Contents
1. Installation Guide L31231 1 08 Installation Instructions for the PR and PR Plus Height Control Valve PR amp PR Plus General Information The Haldex Precision Response PR amp PR Plus Height Control Valves HCV automatically add and exhaust air from any air suspension to maintain a constant static design ride height The PR line of HCV s are perfect for light to heavy duty applications and can be installed on rear air suspension cab air suspension and front air suspension applications The PR and PR Plus line of HCV s offer an array of fittings manifolds and integrated dump valve options The PR and PR Plus HCV can be used in left or right hand installations with short or long control arm configurations The Haldex line of PR height control valves have an industry leading deadzone can operate in hot and cold environments and decrease air consumption NOTE The Haldex PR amp PR Plus HCV s can be interchanged with other brands of height control valves Be sure to read instructions carefully for proper replacement and installation Before You Get Started IMPORTANT The HCV and linkage are designed to maintain the vehicle ride height as loads increase and decrease Proper setup of the PR and PR Plus HCV s is critical to system performance Prior to any assembly or disassembly please read all instructions Should you feel unable to properly perform the installation or adjustments of a Haldex PR or PR Plus HCV contact2. If necessary install fittings in HCV before mounting to the vehicle Haldex recommends fittings with pre applied seal compound If recommended fittings are not available use a drop of oil or thread locker Use small amounts of sealant on threads only DO NOT use Teflon tape or pipe sealing compound 4 Mount the PR amp PR Plus HCV on the frame rail or a bracket and torque mounting nuts to 35 45 in lbs Hexagonal head fasteners can be used to mount the PR HCV Integrated fasteners are already installed in the PR Plus HCV For proper mounting bolt spacing see Fig 1 amp 2 The PR amp PR Plus valves should be mounted as level as possible A small torpedo level or mason s line level can help in this positioning 5 a Connect the air line from the air springs to the delivery DEL port s on the valve b Connect the air line from the air supply tank to the supply SUP port on the valve c Charge the air supply system NOTE Supply port for PR HCV is the port closest to the mounting holes on the valve PR Control Arm Orientation ROADSIDE INSIDE FRAME MOUNTING VEHICLE FRONT gt ALIGNMENT INDICATOR ALIGNMENT INDICATOR ALIGNMENT INDICATOR ALIGNMENT INDICATOR Figure 3 Verify System Operation 6 Confirm the control arm is properly installed by raising the control arm approximately 20 above horizontal Air pressure should inflate the air springs If the air springs do not inflate a Verify the air supply pre
3. Haldex Technical Services or have a certified mechanic install or adjust the valve CAUTION Incorrect installation of any HCV and associated components can impair suspension and vehicle performance It is extremely important that the original equipment manufacturer s specifications of a one or two HCV system be followed when installing an air control system Refer to vehicle and suspension manufacturer s instructions for recommended valve location and ride height DO NOT install a single height control valve of any type if the suspension or vehicle manufacturer speci fies a two height control valve installation DO NOT use a time delay valve with a PR or PR Plus HCV on the same vehicle DO NOT use antifreeze or other solvents in an air supply line Use of solvents or antifreeze can damage seals and void the valve warranty NOTE Conducting routine air system maintenance can help prevent any damage to air system compo nents Never introduce foreign chemicals into any air system Drain all moisture from air reservoirs at regular intervals ALWAYS use a Pressure Protection Valve PPV and filter such as the Haldex Part Number 90554107 Attach PPV directly to the air reservoir for supply to the PR amp PR Plus HCV Reference Dimension Details for PR Plus HCV DUMP PILOT 1 4 TUBE PTC 1 4 18 NPT OR OR 6mm PTC 3 8 PTC OR M12 X1 5 Figure 1 Reference Dimension Details for PR HCV Figure 2 Prepare Vehicle For In
4. d Valve N Suspension Air Spring PR Plus Valve with Dump Supp From Air Tank FA y Air Tonk Figure 7 Suspension Air Spri rs a N SS Front of M PR Valve Vehicle F AA N N S A N __ Suspension Alr Spring S ac SW x Suspension Air Spring F Air Tank Figure 8 __ Suspension Supply Air Spring f 7o From Alr Tank f SA Y l 3 NS PR Valve DR N Suspension Alr Spring Front of Vehicle i Suspension Alr Spring Air Tank Figure 9 Suspension Air Spring Y Se Front of Vehicle KON SRC 4 eo D d CA 4 U Air Springs Linkage Pressure Air Tank Figure 10 Protection Valve To Glad Hand 7 C Suspension or Emergency ax Air Spring Brake Line a T Le Suspension E X Air Spring SA EGAJ Front of SQ LANL Vehicle PR Plus Valve with N C Dump i D i i To Pilot Signal Supply ts a From Air Tank ce R eke To aa CaS gt a z A Se Suspension Alr Springs To Linkage Air Springs These Additional Parts Are Available From Haldex Adjustable Linkages 48100374 Looped Linkage Max Length 16 48100375 Looped Linkage Max Length 22 48100367 Strap Linkage Max Length 14 Add a suspension dump feature to your truck or trailer 48100224 Fixed Rod Linkage Max Length 15 7 8 90554088 For Switch to Pilot Manual Dump nag Valves Upgrade your Pressure Protection Valve to include an inline fi
5. hicle to be parked over an inspection pit or level surface and may require two people working simultaneously when using a two HCV system 13 CHECK LINKAGE S FOR CLEARANCE Disconnect the lower linkage connection and move the HCV control arm down to fully exhaust the suspension Reconnect the lower linkage to verify linkage does not interfere with frame rail electrical wiring or air lines If there is linkage or control arm interference the valve position and or linkage axle tab need to be moved Check For Linkage Interference continued 14 CHECK LINKAGE OPERATION WITH SUSPENSION AT FULL EXTENSION Disconnect lower linkage from axle tab and move the HCV control arm up to raise suspension to full extension IMPORTANT DO NOT continue to inflate air springs after full extension is reached Damage to shock absorbers and or air springs could result Immediately reconnect lower linkage to axle tab Verify the control arm linkage connection rotates smoothly and is free of tension If the linkage is in tension or the rubber link end is being pulled along the rod at full extension the valve position and or linkage axle tab will need to be moved Lowering Exhausting Your Air Suspension Certain applications may require that a vehicles air suspension has the ability to fully lower or exhaust the air springs from ride height The PR Plus HCV has the option of an inte grated Normally Open or Normally Closed dump valve The Normally Open u
6. lter eae 90554107 PPV With Inline Filter 90554615 For Remote Mounted Auto or Manual Dump Applications Upgrade Pressure Protection Valve to include an inline filter 90554107 PPV With Inline Filter Warning The products described within this literature including without limitation product features specifications designs availability and pricing are subject to change by Haldex and its subsidiaries at any time without notice This document and other information from Haldex its subsidiaries and authorized distributors provide product and or system options for further investigation by users having technical expertise It is important that you analyze all aspects of your appli cation and review the information concerning the product or system in the current literature or catalog Due to the variety of operating conditions and applications for these products or systems the user through their own analysis and testing is sole ly responsible for making the final selection of the products and systems and assuring that all performance safety and warn ing requirements are met Commercial Vehicle Systems Haldex Brake Products Corporation 10707 NW Airworld Drive Kansas City MO 64153 1215 Phone 816 891 2470 Fax 816 801 4198 Haldex Limited 525 Southgate Drive Unit 1 Guelph Ontario Canada N1G 3W6 Phone 519 826 7723 Fax 519 826 9497 www haldex com www hbsna com L31231 US 1 08 ART ONLY
7. ncace dump valve is typically V operated in conjunction with a manual switch or electric solenoid valve as shown in Fig 9 The Normally Open dump valve allows air to be exhausted from the air springs when a pilot pres sure is applied The Normally Closed valve is typically operated from the gladhand or emer gency brake line as shown in Fig 10 The Normally Closed dump valve allows Che nii air to be exhausted from INTERFACE CAP the air springs when the pilot pressure is removed It should be noted that the optional dump valve for the PR Plus HCV is NOT sold separately and CANNOT be replaced in the field The Haldex Pilot Valve part number 90554615 can be used in conjunction with the PR HCV to provide air suspension exhausting The Haldex Pilot Valve provides the capability to exhaust air from any air suspension in a Normally Open or Normally Closed operation UNIVERSAL fa RUBBER LINK END 90 ORLESS AT RIDE HEIGHT CONTROL ARM h PR VALVE i LUNKAGE CONNECTION ASSEMBLY i MUST BE IN VERTICAL i ALIGNMENT WITH EACH OTHER PR VALVE PR PLUS VALVE Figure 6 Pressure Protection Valve Suspension 4 Alr Spring From Air Tank Air Springs i Pressure Protection Valve ri X Ky ae rey A Suspension Sf Air Spring From Air Tank To_ Air Springs Pressure Protection Val ve Manual oe Switch a a Electric Solenoi
8. o verify that the suspension is within the manufacturer s specified tolerance 12 FINE ADJUST RIDE HEIGHT IF NECESSARY Carefully adjust the linkage assembly or control arm to bring suspension to ride height Your PR or PR Plus HCV may have an adjustable control arm which provides approximately 1 of ride height adjustment After each adjustment of the linkage or control arm repeat previous step This may require several attempts repeat until proper ride height is obtained twice in a row NOTE When using the adjustable control arm to make fine adjustments torque bolt to 25 30 in Ibs FINAL CHECK Soap spray test all air line connections for air leaks and verify that all fasteners are tight NOTE Ride heights may vary slightly from the loaded to the unloaded condition NOTE The vehicle should maintain air spring volume and remain near ride height during short periods out of service An air suspension system can deflate during extended periods out of service NOTE A small amount of air may escape from the exhaust located under the interface cap this is nor mal and should not cause alarm or require replacement of the valve NOTE If two valves are used on a chassis then the valves must be located in the same position and location on each side of the vehicle Proper installation of a 2 HCV system is required to ensure the air suspension system operates correctly Check For Linkage Interference NOTE The following procedures require the ve
9. ssure is sufficient enough to open the pressure protection valve usually erage Ga PR Plus Control Arm Orientation b Recheck the air lines for prop er port connection VEHICLE FRONT c Make sure that any suspen m AA sion dump exhausting feature 09 e09 is not activated d Determine if the control arm and alignment identifier dim ple on the interface cap are CURBSIDE INSIDE FRAME MOUNTING lt VEHICLE FRONT ALIGNMENT INDICATOR Q j LET a ARM POSITION s J ARM POSION 7 3 ARM POSTION VEHICLE FRONT femmes VEHICLE FRONT in the proper orientation NoxcaToR 3 teal ea Refer to Fig 3 amp 4 ABS cy NS Be If air system still fails to inflate air e GO mie y springs contact Haldex Technical Service gees VEHICLE FRONT ALIGNMENT INDICATOR INDICATOR on bS one On ee POA pOg DOG bOd e e d gt i kanaa tee os A w ig ae a gt VEHICLE FRONT If the PR or PR Plus HCV properly inflates the air springs rotate the control arm down approximately 20 below horizontal During nor mal operation the air is exhaust ed from under the interface cap as shown in Fig 6 Verify air is flowing from under the interface cap and the air springs are deflating Ride Height Adjustment Instructions NOTE The following procedures require the vehicle to be parked over an inspection pit or level surface and may require two people working simultaneously when using a
10. stallation NOTE Prior to installation rotate control arm 3 5 times 360 degrees in both the intake and exhaust directions to remove any adverse effects from storage 1 Be sure that the suspension is centered between the frame rails before beginning installation The vehicle should be in an unloaded condition before starting installation procedures Be certain all dump switches are off Park the vehicle making sure all vehicle wheels are on a hard level surface Raise and properly support all auxiliary axles DO NOT set the parking brakes Instead use safety wheel chocks to secure the vehicle WARNING Failure to support auxiliary axles could allow axle to drop or the vehicle to roll resulting in death or serious personal injury Installing the PR and PR Plus HCV 2 Determine the desired control arm position and valve orientation on the vehicle Fasten the control arm to the interface cap and shaft making sure the alignment identifier dimple on the interface cap is in the proper position for your valve orientation Refer to Fig 3 amp 4 for proper alignment identifier orientation Use the provided nylok nut and tighten to 25 30 in Ibs DO NOT over torque this nylok nut it could result in a damaged or broken shaft NOTE If adjustable control arm is used assemble with provided hardware Torque the adjustment bolt to 25 30in Ibs NOTE Apply permanent thread locking compound on threaded shaft before tightening down the nylok nut 3
11. two HCV system 7 Bring the suspension to the vehicle manufacturer s recommended ride height Ride height is measured from the bottom of the frame rail to the center of the axle Refer to the vehicle or suspension manufactur ers manual for proper ride height measurement 8 With the suspension at ride height and the HCV control arm at center position determine the loca tion of the lower linkage tab A typical PR HCV and linkage assembly are shown in Fig 5 Note the recommended angles between the HCV and linkage connection before installing the bottom linkage tab 9 Damage to the valve linkage and other suspension components may result if the recommended angles are not followed Measure the distance from the control arm linkage mounting hole to the axle tab bracket mounting hole Dim A Fig 5 This is the required linkage length 10 Connect the linkage to the control arm and axle tab bracket For correct linkage assembly consult the suspension service manual IMPORTANT Adjustments to the suspension ride height requires system air pressure Adequate sys tem air pressure must be maintained throughout adjustment procedures 11 CHECK FOR PROPER RIDE HEIGHT Disconnect the lower linkage end from the axle tab Lower the control arm and linkage about 1 and hold for 15 seconds to lower the suspension Reconnect the lower linkage end the suspension should return to ride height Measure the ride height on both sides of the vehicle t
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