Air Line Fitting

3/29/2019

If you are in need of removing an air tank to gain clearance for the purpose of installing a frame component, the new fittings require an air line fitting release tool. The release tools are available to order from your Volvo dealer and are available in plastic (kit part number 85152447) or metal (kit part number 88800414).
To assist you with the new air line fittings, attached is a Design and Function document of the new air tubing and fittings.

Chassis ID Path
565/Description, Design and Function//Air Tubing and Fittings
Model Identity
TE 142060236
Publish Date ID/Operation
6/1/2018

Air tube fitting Air tube Air tube, material Nylon pipe, construction Rubber hose, construction Pneumatic quick fittings Types of pneumatic quick fittings Fitting system Push in fitting system, construction Swivel and building block fitting system, construction Tube, removal Tube, installation
 
Air tube fitting Air tube Air tube, material

The air tube is made up of polyamide material, commonly known as nylon.
To carry the compressed air between components with no or relatively less movement, nylon pipes or rubber hoses are used. To carry the compressed air between components with relatively more movement, only rubber hoses are used.

Nylon pipe, construction

nylon pipe construction

The nylon pipe is a solid core with single ply extrusion. The nylon pipe with outer diameter (D) greater than 6.35 mm, is a solid core covered with protective colored layers with fiber reinforcement between the layers. The cover is resistant to heat and sunlight.

Air tube, material

The hose is about three layers of rubber and reinforcement. The rubber hose is cut to a specific length and fittings are crimped on both ends.

Pneumatic quick fittings

Types of pneumatic quick fittings

quick fitting

 

  • Brass fitting with insertable fitting and threads.
brass fitting
  • Plastic fitting with insertable fitting for assembling the components without threads like footbrake and solenoid valve.
plastic fitting
  • Plastic fitting with insertable fitting without threads for assembling the building block and swivel element with thread.
plastic fitting elbow
  • Insertable fitting which is assembled directly to the swivel element.
insertable fitting
  • Brass or plastic swivel fitting used for connecting building blocks.

swivel fitting

 


  • Brass or plastic plugs used for plugging the ports and connections that are not used.
plastic plug
  • Plastic building blocks used for connecting various fittings.
building block
  • Test nipple used to measure pressure in the pneumatic system.
test nipple
  • Connecting swivel used for connecting fittings with building blocks.

Fitting system

Push in fitting system, construction

Push in fitting system, overview

fitting system


1 Main seal
2 Grip ring
3 Dust seal
4 Polyamide tube
5 Fitting

 

The fitting (5) consists of a dust seal (3) to prevent the entry of dust and other contaminants.


The fitting (5) also consists of a check valve (6) which allows the air to escape when the fitting is
under pressure. The check valve (6) also ensures that the tube is properly inserted into the fitting.

Note: the tube is not properly fitted, there will be leakage of air.

fitting plastic arm

The fitting has a plastic arm (7) which breaks when the tube is installed properly.

Note: A clicking sound will be heard when the tube is installed properly for first time.

Note: The fitting can be used a maximum 5 times either for removal or installation.

Swivel and building block fitting system, construction

The building block (9) has plastic clips (10) on either side which locks the swivel (8).

plastic clips

 

8 Swivel
9 Building block
10 Plastic clip

Air leakage between swivel and building block

air leakage

 

A The fitting is locked but is not sealed.
B The fitting is locked and sealed

 

Leakage of air at (A) indicates that the assembly is not fitted properly.


Tube removaltube removal

To remove the tube, a release tool (11) is used.

Position the tool on to the tube.

Push the tube into the fitting.

Rotate and push the tool to secure it fully into the fitting.

The tool will open the grip ring (2) and prevents the locking of the tube.

Note: The tool should be pressed against the fitting during the tube removal process.

ring pliers


Standard snap ring pliers (12) are used to disassemble the swivel (14) and building block (13) .

While replacing the components like valves, air reservoirs or air bellows, the fittings can be removed along with tube.

Check the condition of O-rings on the fittings.

Note: Ensure that the O-rings are seated properly on the fittings before installing.

Note: If necessary, replace the O-rings.


Tube, installation

Install the fitting on to the component.

Note: Ensure that the component is fixed firmly.

Note: Ensure that the tube is free from dust and other contaminants.

Note: Ensure that there is no visual damages to the tube.

Note: Ensure that the tube ends are straight.

Note: Ensure that the tubes are fitted straight into the fittings.

Torque tighten the fittings.

Tightening torque
Air tube fitting
1. M10x1
15 ±3 Nm (11 ±2 lbf⋅ft)
2. M12x1.5
25 ±5 Nm (18 ±4 lbf⋅ft)
3. M16x1.5
40 ±8 Nm (30 ±6 lbf⋅ft)
4. M22x1.5
40 ±8 Nm (30 ±6 lbf⋅ft)

Tightening torque
Air tank, drain valve M12
17 ±3 Nm (13 ±2 lbf⋅ft)

Push the tube into the fitting until it stops.


Note: A clicking sound will be heard when the tube is installed properly for first time.

Note: The fitting can be used a maximum 5 times either for removal or installation.

Note: Ensure that the tube is fitted properly into the fitting by pulling the tube.

Check for leakage.