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UltraRide Troubleshooting
The UltraRide® Chassis Air Suspension, as with any other air operated system, requires regular maintenance to remain in good operating condition and free from conditions that could cause premature failure of system components. It is very important for this maintenance to take place on the Air Kit to reduce the wear on the compressors.
There are three basic tips that can help prolong the life of your UltraRide.
1. Drain the water from the Air Tank.
• Because the Air Compressor pulls air from an outside source, the compressed air can build up excess water in the air tank. Link provides a drain valve on the end of the Air Tank that can be used to drain this excess water out of the Air Tank. This should be done on a daily basis depending on the outside atmosphere and frequency of compressor run.
• Option: Link does have an automatic drain valve that can be installed on the Air Tank to help drain water from the Air Tank.
2. Clean/Replace the Air Filter on the compressors.
• Attached to the compressors intake port is an Air Filter that will help to keep particulates out of the head of the compressor. This filter should be checked during regular vehicle maintenance.
3. Regular Inspection of Components, Brackets & Fasteners.
‚Because you are driving a vehicle which is in a very dynamic environment, it is important to continually inspect all components, brackets and fasteners during regular maintenance of the vehicle. This should include the following:
‚Component checks: Check to see that all components are operating correctly with no signs of wear or leaks. Check for possible wear marks, fluid leaks, and use soapy water to check for air leaks.
• Bracket checks: Ensure that brackets are mounted correctly and securely. Also, check for cracks on the brackets and signs of movement between the brackets and mount surfaces.
• Fastener Checks: Ensure all fasteners are tightened to the appropriate torque. This should be done within the first 1,000 miles, and periodically thereafter. A quick visual check can be done if the fasteners are marked with a paint mark to show if the fasteners have moved since they were torqued.
Now that we have reviewed maintenance, what do you do if you find some problems during the inspection? There are several options for handling these issues.
1. Review the Owners Manual for possible tips and troubleshooting suggestions for the problem.
• If you do not have a copy of the Owners Manual, they are available on our website, www.linkmfg.com. Please make sure you have the model number of the Suspension or Air Kit you are working on.
2. Contact the Installer of the suspension to see if they can help diagnosis the problem and come up with a solution.
3. Contact a local Authorized Service Dealer or Truck Service Center to have them diagnosis the problem, and work with Link Mfg. to find a solution.
4. Contact Link Mfg. directly to troubleshoot the issue and find a solution.
Here are some tips on how to address the issue of the suspension losing or leaking air:
First apply soapy water to check all fittings, airline connections, and components to see if there is a leak that will be evident with bubbling. Upon finishing the bubble testing and fixing any of the leaks found, it is still possible to have a larger leak that could be connected to one of the following three components:
1. 3 Way Dump Solenoid
‚This is the valve in the air kit that sends the air signal to the dump module on the height control valve in order to dump the air out of the air springs and drop the back end of the vehicle.
• It is possible for the valve to stick open after turning off the dump and have air leak out the bottom exhaust port of the valve.
• In time, this will drain the air out of the reserve air tank and lead to excessive compressor run time.
2. Height Control Valve (HCV)
‚ The HCV is the valve (or valves for dual HCV setup) that is used to control the ride height of the suspension, by filling or exhausting air from the Air Springs.
• It is possible for air to leak around the ports where the airlines attach to the HCV.
• It is possible for air to leak between the different sections of the HCV.
• It is also possible that the valve could leak air straight through the exhaust port.
‚In time, this type of leak can be seen as one side of the vehicle dropping (with the dual HCV setup) or the entire vehicle dropping to the bumpers (with a single HCV setup).
‚This leak may start slowly and eventually can lead to excessive run times for the compressor.
3. Air Line Check Valve
‚The Check Valve is the valve located between the compressor and the air tank that prevents air from flowing back into the compressor after the compressor shuts off. This valve may be part of a Braided Hose Assembly or may be a separate valve.
•A sign of the check valve being faulty would be air coming back through the hose assembly into the compressor head (evidence as bubbling on the head of the compressor when soaped down).
• Another sign of a faulty check valve could be an Air Kit that can not build enough pressure to keep the suspension inflated and, as a result, when an air pressure reading is taken at the tank, it is below the activation pressure of the pressure switch.
‚This may start as a slow leak that drains the air tank as the vehicle sits, and can eventually lead to the failure of the compressor as it attempts to run against the pressure of the air tank.
This information should provide some insight into how the system operates, and what needs to be done to keep the system operating at its best.
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Haldex Guide Troubleshooting
Printable Guide
HCV=Height Control Valve
PTC=Push to Connect
*Refer to installation instructions for your suspension.
1. Determine if HCV control arm is in the proper position for installation. Alignment indicator nub should be clocked at a specific orientation which is dependent upon valve installation. All valves must be installed in accordance with Link installation instructions.
2. Make sure that the control arm and linkage are in the appropriate and recommended. Improper installation may cause damage to components of the HCV and linkage or other suspension components. Refer to the figure below for proper angles when at ride height.
3. Make sure all airlines are cut flush and contain no burrs. Also check that all airlines are firmly pressed into all PTC fittings. Soap spray should be used to determine leakage around air hose fittings.
Note: Under normal operation, air will exhaust from underneath the interface cap of the HCV. This should not cause alarm or require replacement of the HCV.
4. To ensure HCV is working properly, disconnect the linkage from the control arm and raise the control arm approximately 20o above horizontal. Air pressure should inflate the air springs and raise the suspension. Refer to Figure 1-1.
- If the air springs do not inflate:
- Verify that the air supply pressure is sufficient to open the valve (usually greater than 75psi).
- Recheck the air lines for proper port connection.
- If the valve has a dump feature, confirm the dump switch is not activated.
- Determine if the control arm and alignment identifier dimple on interface cap are in the proper orientation.
5. If HCV properly inflates the air springs, rotate the control arm down approximately 20o below horizontal. During normal operation the air is exhausted from underneath the interface cap of the valve.
6. Check linkage(s) for clearance. Disconnect lower linkage connection(s) and move the HCV control arm(s) down to fully exhaust suspension. Reconnect lower linkage(s) to verify linkage does not interfere with frame rail, electrical wiring or air lines. If there is linkage interference, the valve position and/or linkage axle tab need to be moved.
7. Check linkage operation with suspension at full extension. Disconnect lower linkage(s) from axle tab(s) and move the HCV control arm(s) up to raise suspension to full extension. Immediately reconnect lower linkage(s) to axle tab(s). Verify the control arm/linkage connection rotates smoothly and is free of tension. If the rubber link end is being pulled along the rod at full extension, the valve position and/or linkage axle tab(s) will need to be moved.
Important Note: Do Not continue to inflate air springs after full extension is reached. Damage to shock absorbers and/or air springs could result.
8. Lower the vehicle below the designated ride height. Once below ride height, bring the suspension to the recommended ride height. Re-attach the linkage to the control arm, making any adjustments if necessary.
Figure 1-1
Note: If the HCV has a dump feature it is best to dump the suspension and re-measure the ride height. If working with a 2 HCV application it is best to set the ride height of both HCV’s simultaneously.
Important: When vehicle is raised above ride height, the linkage should not be put in tension or pull on the HCV control arm. If this occurs during full extension the valve position and/or linkage axle tab will need to be moved.
Note: Ride heights may vary slightly from the loaded to the unloaded condition. The vehicle should maintain air spring volume and remain near ride height during normal periods of service. If the system deflates, check fittings, hoses and air springs for leaks. Using a soap spray can help identify leaks.
Note: The PR HCV will fill to within 98% of ride height within 1 minute. It may take another 20 seconds to a minute for the valve to settle into the neutral zone. This is how the PR valve conserves air near the deadzone. The flow profile tapers off near the deadzone to decrease air consumption.
Note: Setting the ride height for a 2 HCV application requires the neutral zones of each valve be in line with each other. This may require adjusting the adjustable control arm several times to ensure that proper ride height is obtained. It is best to exhaust or dump the suspension below ride height and then allowing the vehicle to come to ride height. Measure the ride height. If not correct follow ride height procedures again.
Finding Leaks in the HCV
1.) Verify correct port labels & locations
a. Ports should be labeled as follows:
i. SUP (this is the valve supply port)
ii. DEL 1 (this is an air spring port – Not used)
iii. DEL 2 (this is a second air spring port)
iv. The Dump pilot port has no label.
b. All ports should be 1/4” PTC fittings
c. Ensure that the manifold is oriented properly for your suspension.
2.) Verify proper Drive Collar Indicator Orientation & Flow Paths
Refer to Figure 1-1.
a. Rotate the control arm so the indicator is in the Exhaust Region
b. Connect a 100 psi supply pressure to the SUP port on the HCV
i. Air should flow out from the DEL 2 port when the drive collar indicator is within the Fill Region
ii. No air should exhaust when the Drive Collar Indicator is within the Exhaust Region (can be checked using a bubble bath)
c. Connect at 100 psi supply pressure to the DEL 2 port (Keeping the SUP port connected to a 100 psi supply).
i. Air should exhaust out from behind the Drive Collar when the indicator is within the
Exhaust Region
ii. No air should exhaust when the Drive Collar Indicator is within the Fill Region (can be checked using a bubble bath).
3.) Verify Internal Check Valve Operation
a. Rotate Drive Collar Indicator to the Exhaust Region
b. Apply 100 psi supply pressure to the SUP port
c. Remove the supply air from the SUP port – completely removing the hose from the SUP fitting.
No hoses should be connected to the HCV
d. Wait 1 min.
e. Rotate the drive collar indicator to the Fill Region
i. A spurt of air should flow from the DEL 2 port. The spurt of air indicates the supply port check valve is working properly and some air was trapped in the supply path of the valve.
ii. If there is no spurt of air from the DEL 2 port, either the supply check valve is not working properly, or there is a leak somewhere else in the valve.
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