Procedures

WM 4301IN Filling specification for air-spring strut

Tools





Technical values





Overview

Information

The graphics in this document may differ from the original, but this does not affect their validity and relevance.

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Filling unit





General information

The air-spring struts are pre-filled to approx. 2.5 bar overpressure ex-works. If a new air-spring strut is installed, air can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use. The procedure is described in detail in the course of the repair instructions.

Filling the air-spring strut

WARNING

Working with compressed air

- Risk of eye injuries
- Risk of damaging and dirtying components

-> Wear protective goggles with side eye protection.
-> Protect the point at which the compressed air emerges with suitable material.
-> Place the point at which the compressed air emerges on suitable surfaces.

1. Remove the protection cap from the pressure control valve. Carefully remove any remaining packaging. Make sure not to damage the protective bellows during the filling process.
2. Screw the adapter T10157/1 from the filling unit onto the pressure control valve at the correct position.





Information

- The air-spring strut must only be filled with the approved gasses, nitrogen or oil-free compressed air.

- In some cases, up to 11 bar overpressure (upper tolerance, spring strut depressurised) is required to open the pressure control 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 2.5 bar.

4. Fit the => see figure filling unit to the pressure gauge unit of the compressed air bottle.





5. Set the => see figure pressure gauge unit (flow limiter) to approx. 20 l/min -arrow-.





Information

The air-spring strut is empty if the rubber bellows can be pressed in slightly.





Checking air bellows (shown as an example)

6. Carefully overcome the counter-pressure of the pressure control valve with three to four short individual pressure shots and fill the air-spring strut. Do not exceed the maximum => Pressure: +2.5 bar!
6.1. Check the rubber bellows several times during the filling process to see if it can be pressed in. Sufficient air is filled in when the bellows can no longer be pressed in slightly.
6.2. If the length of the air-spring strut changes during the filling process, enough air has been filled in.
6.3. When sufficient air has been filled, quickly pull off the connection from the pressure control valve. Pulling off the air-spring strut filling unit VAS 6231 00000 quickly, prevents gas from escaping from the air-spring strut. Repeat the filling process if necessary.
7. Once the air-spring strut has been filled correctly, it can be removed from the transport packaging and fitted.