APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

Function
BR5504
The Load Sensing Valve is used to modify the applied service
brake pressure in relation to the load imposed on the vehicle’s
axles. The air suspension Load Sensing Valve uses the pressure in
the air suspension bags to ‘sense’ the load imposed on the axles
BR5524
and determine the valve’s braking ratio.
Versions of the valve are available with and without relay and relay
emergency features, also with static or dynamic operation. The
relay emergency feature provides automatic braking on a trailer
in the event of a breakaway. A static valve uses the braking ratio at
commencement of braking application. A dynamic valve adjusts BR5522
the braking ratio throughout the brake application to help coun-
teract the effect of load transfer.
A data plate, showing the settings of the vehicle’s Load Sensing
Valve, is required by law (See page 3).
Standard Symbol as DIN ISO 1219
BR5504
Technical Features
1 1-2
Maximum Operating Pressure: 8.5 bar 3

Operating Temperature Range: -40 °C to +80 °C

Weight: see table 2
2
2
2
2
Range Overview 2

Relay 43 41 42 4 BR 5504a

Weight
Part No. Type No. Operation Emergency Relay feature
approx. [kg]
Valve BR5522
K037584 1) BR5504 static or dynamic with with 3.1
II36836 BR5522 static without without 2.1 1 2
K037587 1) BR5524 dynamic with with 3.0 3 2

Test Point Basic setting

Air Suspension
Part No. Type No. connection
connection Unladen Laden
“43” 43 41 42
p1/p1-2=8 bar; p4=6.5 bar BR 5522a
K037584 1) BR5504 with p41 / p42 p41/p42=0.8 bar p41/p42=5.1 bar
p2=2 bar p2=6.5 bar BR5524
p1=6.5 bar
1 1-2
II36836 BR5522 with p41 / p42 p41/p42=0.6 bar p41/p42=4.6 bar 3
p2=2.6 bar p2=6.5 bar
p1/p1-2=8 bar; p4=6.5 bar
2
K037587 1) BR5524 without p42 p42=0.5 bar p42=4.4 bar 2
p2=2 bar p2=5.2 bar
Other versions are available.
1)
The part number will carry a suffix “N00” which defines that it is supplied without packaging. Example K037584N00.
42 4 BR 5524a

1/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

Air Port Threads

Part No. Type No.
1 1-2 2 4 41/42 or 42
M16x1.5 (4x)
K037584 BR5504 M16x1.5 M22x1.5 M16x1.5 M12x1.5
M22x1.5 (2x)
II36836 BR5522 M22x1.5 – M16x1.5 (2x) – M12x1.5
K037587 BR5524 M16x1.5 M22x1.5 M22x1.5 (2x) M16x1.5 M12x1.5

Performance charts

Typical SettingTypical Setting

pressure

β P1 = 7.5 Bar
pressure

1 = Pressure in the Supply Line [bar]

βm

7.5
of minimum

2 = Pressure in the Brake Actuators [bar]

ax.
of minimum

P2c
3 = Signal pressure p [bar]
4 = Delivery pressure p2 [bar]
range

6
in.
Adjustment

βm

P2v 5 = Control Pressure p41 p42 [bar]

Adjustment

Adjustmentininthis
this range
range isisnot
6 = Delivery pressure p [bar]
Adjustment notpossible
possible 2
1.1
A = Initial charging
P41c/P42c
0
0.25

2.5

6.5
P41v/P42v

Control
Control Ratioratio EmergencyBraking
Emergency Braking
8 8 A
7 7
6 6
5 1 5
4 1/ 2
4 4
3 3
2 2
1 1/8 1
0.4+-0.1
0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8
0.3 Max.
3 1
only for BR5504 and BR5524

2/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

Load Sensing Valve Data Plate for pneumatic Load Sensing Valve BR55.. Part No.: EB00669

KNORR-BREMSE
T S/A
R e s s o r t No Supplied with:

II36836 - BR5522
P1 bar K037587 - BR5524
bar bar
P4 P2
P4 P2

The fitting of the data plate is essential to ensure that the optimum performance from the Load Sensing Valve can be main-
tained once the vehicle is in service.

The plate should be stamped with the following data:

T = Part No. of the Load Sensing Valve fitted to the vehicle

S/A = Date of fitting (Week/Year).

P1 = The inlet pressure at the Load Sensing Valve (used for setting unladen & laden valve ratios)

P2 = The outlet pressures required when the Load Sensing Valve is set correctly (unladen & laden)

P4 = The air suspension bag pressures for the unladen & laden weights.

3/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

Dimensions

BR5504 - K037584

28 28
20 20 9
M22x1.5
Knorr-Bremse

M8

58.4
N10172 M16x1.5
N10172
M16x1.5
N10172

62
71.5

81.8
88
102
95

119
1 1-2

180
2
Ø16

19
10
Ø12

Ø44
3 M22x1.5
N10172
208 116 15 15
367

110
53.4 84
53 42 42
17.4

M8
2.5 A/F
58.4

R8

s S
M12x1.5
132.2
102

N10172

84
1
66

D
test connection D s D
S
for p41, p42
27

42 41
43 52.5

15
30
69.7

Ports: Ports:
1 = Supply
1 = (from
Supplyred trailer
(from red coupling)
trailer coupling)
SS = "Static"
"Static"setting
setting
1-2 = 1-2 = reservoir
Trailer Trailer reservoir
2 = Delivery to brake actuators
2 = Delivery to brake actuators
3 = Exhaust DD = "Dynamic" setting
"Dynamic" setting
3 = Exhaust
4= Signal (from yellow trailer coupling)
41 = Signal (from air suspension)
4 = Signal (from yellow trailer coupling)
42 = Signal (from air suspension)
41 = Signal
43 = (from air suspension)
Test connection
42 = Signal (from air suspension)
43 = Test connection

4/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

BR5524 - K037587

28 28
9
Knorr-Bremse M16x1,5
N10172 M8

58,4
M16x1,5
N10172

62
71,5

81,8
88
102
1 1-2
M22x1,5

180
N10172 2 2

19
10
M8
Ø12

Ø44
3 M22x1,5
208 N10172
332

110
53,4 84
53 42 42
17,4

M8
SW 2,5
58,4

R8
102

84
122

M12x1,5
1
N10172
66

27

42
52,5

15

69,7

Ports:
Ports:
1 1== Supply
Supply(from
(from red
red trailer coupling)
trailer coupling)
1-2= = Trailer
1-2 Trailerreservoir
reservoir
2 = Delivery to brake actuators
2 3= = Delivery
Exhaust
to brake actuators
3 4== Exhaust
Signal (from yellow trailer coupling)
4 42= = Signal
Signal(from
(fromyellow
air suspension)
trailer coupling)
42 = Signal (from air suspension)

5/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

BR5522 - II36836 110 110

53
M8
M22x1.5

58
1
20

17

M16x1.5
60
107.5

SW 2.5
2
149

10

35
22
ø44
SW 13 3
21
8 ø42
67 229

M12x1.5
84
15 42
30 31 17
2 x M16x1.5
ø18
42
41
52

84
40

43
17

ø20
Ports:
88
1 = Signal (from Foot Valve on trucks and tractors)
(from Relay Emergency Valve on trailers)
2 = Delivery to brake actuators
3 = Exhaust
Ports:
41 = Signal (from air suspension)
1= Signal (from Foot Valve on trucks and tractors) 42 = Signal (from air suspension)
(from Relay Emergency Valve on trailers)
43 = Test Fitting
2 = Delivery to brake actuators
3 = Exhaust
41 = Signal (from air suspension)
42 = Signal (from air suspension)
43 = Test Fitting

Checking and adjustment

Relay Emergency Relay Air Port Threads

Part No. Type No. Operation
Valve feature 41 42 43
K037584 BR5504 Static/Dynamic with with X X X
II36836 BR5522 Static without without X X X
K037587 BR5524 Dynamic with with – X –

6/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

Explanation of the port characteristic

• Supply pressure in valves with Relay feature. Connected to Reservoir
Port 1 • Signal pressure in valves without Relay feature
• Supply pressure in valves with integrated Relay Emergency Valve. Connected to Supply (Red) Line
Port 1-2 Supply pressure (in valves with integrated Relay Emergency Valve). Connected to Reservoir
Port 2 Controlled output pressure
Port 4 Signal pressure (only valves with Relay feature). Connected to Foot Valve or Control (Yellow) Line on trailers
Port 41/42 Air suspension bellows pressure
Port 43 Simulation port (allows simulated bellows pressure for adjusting the load sensing valve)

For adjusting the valve ratio, the following steps are necessary:
1. Set “static” or “dynamic” (only BR5504).
2. Adjust output brake pressure p2 “unladen”.
3. Calculation and adjustment of the average value of the characteristic.
4. Check the output brake pressure p2 “laden”.
5. Check the responsiveness.
6. Adjustment of the minimum brake pressure.

Following tools are needed to adjust the load sensing valve:

• Open ended spanners sizes 10, 13 and 19 mm
• Hexagon Allen Key size 2.5 mm
• Slot-head screwdriver

Important notes:
• Read the pressure values from the Load Sensing Valve Plate or from the brake calculation
• Keep the type label free of paint
• Pressurise the ports from 0 bar up to the required pressure. If the charging is interrupted or if the required pressure is not
reached, repeat the charging from 0 bar up to the required pressure
• When adjusting the valve, the signal pressures (input and air suspension) must be reduced to zero
• The exhaust port must point downwards.
• Ensure the exhaust is masked during any painting of the vehicle.

1. Adjustment “static/dynamic” (BR 5504 only)

Exhaust any pressure in Port 4, test valve is not connected.

static: push in screw “E” and turn in clockwise direction from “D” to “S” (90°)
dynamic: push in screw “E” and turn in anti-clockwise direction from “S” to “D” (90°)

7/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

2. Adjustment of the brake output pressure p2 “unladen”

• Refer to pages 9 & 10 - Release lock nut “a”, undo screw “A” for BR5504 up to dimension 24 mm and for BR552. up to dimension
45 mm. Tighten lock nut “a”.
• Loosen grub screws “b” and “c”.
• Supply quoted “unladen” suspension pressure to port 42.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check quoted “unladen”
output brake pressure is achieved.
• If value is not correct, remove input pressure and turn screw „B” whilst holding screw “C” (clockwise to increase pressure)
• Re-apply input signal pressure and check delivered pressure. Repeat as necessary.

3. Calculation and adjusting the average value of the characteristic line

Formula: p2 average value = (p2 laden + p2 unladen) / 2
p41/42 average value = (p41/p42 laden + p41/42 unladen) / 2
Example: p2 average value = (6.5 + 2.4) / 2 = 4.45
p41/42 average value = (3.6 + 0.4) / 2 = 2.0

Adjusting the average value:

• Supply calculated “average” suspension pressure to port 42.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check calculated
“average” output brake pressure is achieved.
• If value is not correct, remove input pressure and turn screw “C” whilst holding screw “B” (clockwise to decrease pressure)
• Re-apply input pressure and check delivered pressure. Repeat as necessary.

4. Checking of the brake pressure p2 “laden”

• Supply quoted “laden” suspension pressure to port 42.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check quoted “laden”
output brake pressure is achieved.
• If value is not correct, remove input pressure and turn screw “C” whilst holding screw “B” (clockwise to decrease pressure)
• Re-apply input pressure and check delivered pressure. Repeat as necessary.

5. Checking the responsiveness

• Supply pressure to the suspension signal port(s) or test valve at a value 0.3 bar higher than the quoted “unladen” suspension.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check that output brake
pressure is slightly higher than the quoted “unladen” value.
• If the output pressure is not higher repeat adjustment, see item 2.
• Supply pressure to the suspension signal port(s) or test valve at a value 0.3 bar lower than the quoted “laden” suspension.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check that output brake
pressure is slightly lower than the quoted “laden” value.
• If the output pressure is not lower repeat adjustment, see item 3.

8/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

• Tighten screws b and c with 1.5 Nm after exhausting the suspension signal port(s) or test valve.
• Repeat the unladen, laden and responsiveness checks.

6. Checking of the brake pressure p2 “laden”

• Ensure there is no pressure at the suspension signal port(s) or test valve.
• Supply input pressure to port 1 (BR5522) or port 4 (BR5504, BR5524) with quoted input pressure and check that the output
pressure is 0.1 - 0.2 bar lower than the quoted “unladen” value. This represents the minimum brake pressure in the event that
the suspension pressure is lost.
• If necessary release lock nut “a” and adjust the minimum brake pressure by turning screw “A” (clockwise rotation = pressure
increase).
• Tighten lock nut “a”.

BR5504
4

Test connection
E
Test connection
for output
for output brake
1 brake pressure
pressure
a 1-2 c b
2 41 42

A
2 2
3 C B
Legend:
Legend: Testvalve
Test valve

S
S =screw
"Static"
S s

slotsetting
horizontally= static

D =screw
"Dynamic" setting = dynamic
slot vertically
D s

BR5522

testvalve
Test valve

2 c b
testvalve
Test valve
43 43
41

A
3 C B 3
a

9/10
 APRIL 2019

PD-104-000
PRODUCTDATA Doc. No. Y011345 (EN- Rev. 006)

BR55..
Load Sensing Valves (Air Suspension)

BR5524

Servicing
The Load Sensing Valves BR5504, BR5522 and BR5524 are not serviceable.

Revision Details
Rev. 006 April 2019 New Layout

Up-to-date information on our products can be found on our

Knorr-Bremse Systems for Commercial Vehicles
Moosacher Strasse 80 | 80809 Munich | Germany
Tel: +49 89 3547-0 | Fax: +49 89 3547-2767
W W W. K N O R R - B R E M S E C V S . C O M
Note
All information is subject to change. A printed version of this document may therefore
not correspond to the latest revision. To obtain the latest version, please visit our website
www.knorr-bremseCVS.com or contact a Knorr-Bremse representative in your area.
If service work is carried out on a vehicle based on information provided herein, it is the
responsibility of the workshop to ensure the vehicle is fully tested and in full functional
order before the vehicle is returned into service. Knorr-Bremse accepts no liability for
problems caused as a result of appropriate tests not being carried out.
website www.knorr-bremsecvs.com
Disclaimer
The information contained herein is intended for the exclusive use of trained persons
within the commercial vehicle industry, and must not be passed on to any third party.
All recommendations regarding products and their servicing or usage are with reference
to Knorr-Bremse products and should not be considered applicable to products from
other manufacturers.
This information does not purport to be all-inclusive and no responsibility is assumed as
a result of its use. We cannot accept any liability nor offer any guarantee regarding data
accuracy, completeness or timeliness.
The information does not represent any guarantee or ensured characteristics of the
Products or Systems described. No liability can be accepted based on the information,
its use, recommendations or advice provided. In no event may we be held liable for any
damage or loss except in the case of wilful intent or gross negligence on our part, or if
any mandatory legal provisions apply.

Copyright © Knorr-Bremse AG This disclaimer is an English translation of a German text, which should be referred to
All rights reserved, including industrial property rights applications. Knorr-Bremse AG for all legal purposes. Any legal disputes arising from the use of this information shall be
retains any power of disposal, such as for copying and transferring. subject to German law.

10/10