Filling Specification For Air-Spring Strut

Filling specification for air-spring strut
General
The air-spring struts are pre-filled with approximately 3 bar overpressure ex-works. If a new air-spring strut is installed, air can diffuse (escape) from the rolling lobe of the air-spring strut as a result of storage times of varying durations. If the air-spring strut is removed from the transport packaging and installed without being filled, the rolling lobe can fall into folds, thereby damaging the air-spring strut. All air-spring struts must be re-filled prior to use for this reason! The procedure is described in detail in the course of the repair instructions.

Filling the air-spring strut

Caution! Observe the relevant operating regulations for handling compressed air and gas filling units. Observe accident prevention regulations.

Note!
^ Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to the inner rolling lobe.
^ The air-spring strut must be screwed securely in the transport packaging during filling.
^ During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring strut.
^ After installation, first set the high level, then revert to normal level. Repeat this procedure once more. This procedure replaces most of the gas with the cleaned air from the air supply unit.

1. Remove transport packaging lid.
2. Pull off protective cap on residual pressure restraint valve. Carefully remove any left-over packaging.





3. Pull off plug connection on residual pressure restrain/valve (a/f 12) and screw on the filling unit -adapter T10157/1- at the correct position on the residual pressure restraint valve.

Note!
^ The air-spring strut must only be filled with the approved gasses, dual-process gasses Argon and Corgon.
^ In individual cases, up to 11 tear overpressure (upper tolerance, spring strut depressurised) is required to open the residual pressure restraint valve.
^ Fill the air-spring strut using several individual pressure shots. Filling the air with individual pressure shots will prevent the air-spring strut from being filled with too much overpressure.
^ Do not fill the air-spring strut with overpressure of more than 4.5 bar.
^ The residual pressure restraint valve automatically reduces excessive overpressure to the minimum overpressure of approximately 3 bar.





1. Fit the -filling unit- to the pressure gauge unit of the compressed air bottle.





2. Set the -pressure gauge unit (flow limiter)- to approximately 201/min .





3. Overcome the counter-pressure of the residual pressure restraint valve with several individual pressure shots and fill the air-spring strut. When sufficient air has been filled, between -3.5 and 4.5 bar (arrows)-, pull off the connection on the residual pressure restraint valve. Do not exceed the maximum value of 4.5 bar.
4. Once the air-spring strut has been filled correctly, it can be removed from the transport packaging and fitted.