Technical - Valve Installation

Note: For component identification and valve porting information, please refer to our Technical page, under KOTR Exploded View/Valve Porting.

Inspection

Before beginning the installation of a new Valve check all air line tubing, fittings, air shocks or springs and other components that are tied into the air system. Inspect for cuts, punctures or other damage that may cause an air leak or not allow the HCV to not function properly. Repair any problems before continuing with installation.

Inspect the HCV Control Link that was previously removed from the HCV. Make sure that the rubber bushings are still flexible; if not, replace the Control Link when installing the HCV. These can become dried and brittle and put undue wear and tear on the HCV and shorten its life.

Preparation

Clean the mounting surface where the HCV will mount. Make sure that dirt and debris are removed from the mounting holes. Thoroughly clean the two air line fittings that will attach to the HCV. Preventing dirt from entering the HCV will ensure a long trouble free life from your new HCV.

Note: If your model uses straight SAE threads check the new HCV to make sure the gaskets are properly installed in the bottom of each air line fitting.

Note: Do not use thread sealant on any of the air line fittings. It is not required for a proper seal and can cause the HCV to malfunction if the sealant enters the HCV or other system components.

Installation

Attach the HCV in the original mounting location. Tighten the two bolts.

Connect and tighten the two air line fittings to 50-60 in-lb (5.5-6.5 N-M).

Note: Do not loosen the lock nut on the HCV control Arm as it is factory preset. Connect the Control Link to the HCV Control Arm and lightly tighten. Over tightening may cause the HCV to not function properly. Connect the other end of the Control Link to its mounting bracket.

Pressurize the air system to normal operating pressures. Check air line connections using a soap-water solution and watch for bubbles which would indicate an air leak. If bubbles are present gently tighten the air line fitting until the bubbles stop. Do not add any type of sealant to stop leaks.

Height Adjustment

Check the equipment height per the equipment manufacturer’s instructions and recommended height specification.

If adjustment is required:

For Fixed Length Control Links...
Loosen the Lock Nut on the side of the HCV Control Arm using a 7/16” hex wrench. Move the Overtravel Safety up to increase the height and down to reduce the height. Tighten Lock Nut to 70-80 in-lbs (8-9 N-M) and re-check the height. If it is necessary to make height adjustments greater than that allowed by the adjustment built into the valve overtravel mechanism, it will be necessary to change to a different length link.

For Adjustable Length Control Links...
Do not loosen the Lock Nut on the HCV control Arm as it is factory preset. Follow the Control Link manufacturer’s instructions to adjust the Control Link, which will then change the height of the vehicle or equipment.