Kits 25852 and 25856
Contents
1. 13 Frequently Asked lt 13 Tuning the Air 13 Guidelines for Adding 2 liiis nen 14 Warranty and Returns 15 Replacement Information 16 Contact Information 16 a Load Controller Dual Introduction NOTE The purpose of this publication is to assist with the installation of the Load Controller Dual onboard air management system It is important to read and understand the entire installation guide before beginning installation or performing any maintenance service or repair The information here includes a hardware list and step by step installation information Air Lift Company reserves the right to make changes and improvements to its products and publications at any time Contact Air Lift Company at 800 248 0892 or visiti us online at www airliftcompany com for the latest version of this manual IMPORTANT SAFETY NOTICE The installation of this kit does not alter the Gross Vehicle Weight Rating GVWR or payload of the vehicle Check your vehicle s owner s manual and do not exceed the maximum load listed for your vehicle Gross Vehicle Weight Rating The maximum allowable weight of the fully loaded vehicle including passengers and cargo This number along with other weight l2. 1 24539 Fuse Holder 1 J 24752 Center Butt 12 10 GA Shrink Tube 2 K 24524 3 16 Terminal FSpd 1 L 24595 FSpd Terminal 12 GA 1 M 24543 Fuse AGC Mrr 1 N 24561 Mini Fuse 1 24542 ATC ATO Fuse In 1 4 1 24594 1 4 Terminal FSpd 16 GA 1 Q 10466 BY Zip Tien cete 5 R 21838 Tee Union 1 4 X 1 4 PTC 2 S 17441 8 18 1 Tek 2 T 26061A 1 U 21275 Tee Hose amp Check Valve 2 V 24592 1 4 Terminal FSpd 16 22 GA 3 Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part 4 MN 746 Dual Analog Gauge Electrical Schematic Load Controller Dual GNNOYD SISSVHD 5 WuOSSdHudWOD fig 2 7502 34 INO 507519 901 34 8700 1Y GNNOYD SISSWHD Av 138 YOSSIUdWOD STVNINYAL NVWA 901 34 VrOO IV 5 VSL HOLIMS 3unss3ud 3avas 319134 1 HOLIMS 02 44 TV 3 0 55384 DIS dWOD V50 A9 29001V ANNOY V50 Ag 0019 3015110 37DIH3A IHL AGISNI STVNINYAL
3. 12 Load Controller Dual Route air lines into cab from fitting and attach to pressure switch assembly as shown in the pneumatic schematic figs 3 and 10 Route air lines from low pressure switch to gauge barb Press air line over gauge barb Water or lube may assist in securing air lines over the barb A circular motion will assist in installation 6 Connect the power wire to fused ignition a Route it to the vehicle fuse box b Determine which open terminal accessory etc works only when the key is in the or accessory position or refer to the owners manual for an available accessory fuse The terminal should have an amperage rating higher than the 15 amp in line fuse Connection to the fuse terminal will depend on what type of fuse your vehicle uses If your vehicle uses the barrel type fuse use adapter 1 If you have the standard spade type fuses use adapter 2 Many late model vehicles use a smaller spade type fuse which requires adapter 3 fig 16 If you use adapter 1 or 2 you will need to crimp on a 1 4 14 16GA female connector supplied in kit If you use adapter 3 you will need to crimp on 3 16 14 16GA female connector supplied in kit The harness comes with blunt cut wire so no cut off is necessary Just crimp the wire right to the connector Adapter 1 Adapter Fuse fig 16 Uses 3 16 smaller Female Push On Connect
4. 3 Install the compressor unit a Hold the compressor in the recommended location fig 11 or 12 b For box frames In some cases the frame section will not be wide enough to mount the compressor legs flat to the rail Refer to figs 11 and 12 in this situation DO NOT DRILL ANY HOLES INTO THE FRAME OR THE FLOOR BOARD BEFORE CHECKING FOR HYDRAULIC LINES GAS LINES AND OR ELECTRICAL WIRES THAT MAY NEED TO BE MOVED ASIDE ALSO WHEN ATTACHING TO THE FLOOR BOARD IT IS IMPORTANT TO CHECK WHERE THE SCREWS PROTRUDE THROUGH THE FLOOR BOARD IT MAY BE NECESSARY TO TRIM OR COVER THE TOP OF THE SCREWS INSIDE THE VEHICLE A SEALER SHOULD BE USED AROUND THE SCREW TO PREVENT THE ELEMENTS FROM ENTERING THE CAB AREA 10 Load Controller Dual STANDARD DUTY COMPRESSOR MOUNTING FIG 1 A1 11 In some cases the mounting area does not provide enough room to use a drill to drive in the screws It may be necessary to use the mounting brackets as a template to drill 13 64 holes through the frame first and then use a 7 16 nut driver to install the self tapping screws 5 Frame Floor pan Eum i L bracket Supplied self tapping screw Bolt and nut will need to be provided if the L bracket is fabricated The L bracket is shown as an optional mounting method and is not supplied HEAVY DUTY COMPRESSOR MOUNTING FIG 1 A2 12 Using the compressor as a te
5. Uses 3 16 smaller female push on connector In line 15 AMP fuse H and fuse holder 1 Low pressure sensors D ponen Butt yellow connector J ES Grommet G gt Firewall Relay PIA Y Ji D 2 2 ZZ _ 7 Female spades PIA Ground Female spade L Power red wire Harness C Check valves Ground A1 standard duty compressor Air springs previously installed Filter Check valves NOTE THIS IS NOT ks AN ELECTRICAL SCHEMATIC BUT A LAYOUT OF THE CONTROL SYSTEM Power red wire SEE PAGE 5 FOR Ground ELECTRICAL A2 heavy duty compressor DIAG RAMS Butt yellow connector J Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part MN 746 3 fF Load Controller Dual Hardware List ltem Part Description Qty A1 16060 Standard Duty Compressor 1 A2 16092 Heavy Duty Compressor 1 B 25195 Analog Dual 1 C 26918 Harness Dual Analog Gauge 1 D 26042 Sensor 5 42525524 2 E 20946 1 4 Air Line 50 F 25196 Gauge Mounting 1 G 10463 1 H 24652 Spade Fuse 15 Amp
6. 3avas YW 3avas YWA 39nv9 SOIWNV MN 746 Load Controller Dual Dual Analog Gauge Pneumatic Schematic 9 150 39nv5 E S3HOLIAS 553 lSnVHX3 3 3 JIHJA SHL Q 1114 Xnv sour s6uuds ya pue ybu 40 J0je2Ipul ue se m s ues ade paJoJo2 55 Q SAAWA MO3HO Z 9NIHdS L ONIHdS 3DIH3A 1 3015110 180d 1114 XNV 11223 MN 746 8 Load Controller Dual Dual Analog Gauge Mounting Options Airline O Airline Power Wires fig 6 Dual analog gauge mounting Dual analog gauge mounting hardware on bottom of gauge hardware on top of gauge Back of analog gauge fig 7 Optional Dashboard Mounting 5 Exploded View MN 746 7 fF Load Controller Dual Installing the Load Controller Dual System RECOMMENDED COMPRESSOR LOCATIONS Important LOCATE COMPRESSOR IN DRY PROTECTED AREA ON VEHICLE DIRECT SPLASH OR EXCESSIVE MOISTURE CAN DAMAGE THE COMPRESSOR AND CAUSE SYSTEM FAILURE Disclaimer If you choose to mount the compressor outside the vehicle please keep in mind the compressor body must be shielded from direct splash and the intake should be snorkeled inside the vehicle If the compressor does not include a remote mount air filter or if mounting the compressor outside the vehicle make sure to orient the compressor intake fil
7. Road Lansing MI 48917 PO Box 80167 Lansing MI 48908 0167 Toll Free 800 248 0892 Local 517 322 2144 Fax 517 322 0240 www airliftcompany com Printed in the USA
8. diameter hole and install the provided grommet fig 15 It will be necessary to seal any grommets or holes that have been cut drilled or removed so as not to allow elements to enter the cab area of the vehicle After the hole is drilled and before you route the harness to through the firewall insert the grommet and walk the material around the inside edge of the drilled hole You may have to trim the grommet to get an exact fit ae The flexible grommet is in the sealed parts package When routing the wiring harness it should not be routed so as to lay on or near the exhaust pipe muffler catalytic convertor of the vehicle Routing along the top of a crossmember or over a heat shield is recommended 5 The next connection is between each air spring and the air line T fitting a With the air springs deflated use a hose cutter to cut the air line already installed between the air springs and the inflation valves Install the provided T fittings fig 1 by pushing the air line into each leg of the T until you feel a definite click Each line should go in 9 16 Connect a single length of air line to the open leg of the Connect as shown in the pneumatic schematic Route the air line across the chassis from the far side over the exhaust system heat shields and along the frame up to the compressor Avoid heat sources sharp edges and tight bends 11 8
9. MN 746 061504 8139 Load 5 Dual by AIR LIFT Kits 25852 and 25856 Dual Gauge Analog Compressor Systems INSTALLATION GUIDE For maximum effectiveness and safety please read these instructions completely before proceeding with installation Failure to read these instructions can result in an incorrect installation TABLE OF CONTENTS 2 Important Safety Notice 2 Notation 2 Installation Diagram 3 Hardware 51 4 Dual Analog Gauge Electrical Schematic 5 Dual Analog Gauge Pneumatic Schematic 6 Dual analog Gauge Mounting Options 7 Installing the Load Controller Dual System 8 Recommended Compressor 8 Getting Started sceri ahaa gt 8 Step by Step Installation liliis 9 Standard Duty Compressor 10 Heavy Duty Compressor 10 Air Line and Power Wires Routing for the Standard Duty Compressor 10 Air Line and Power Wires Routing for the Heavy Duty Compressor 11 Product Use Information
10. imits as well as tire rim size and inflation pressure data is shown on the vehicle s Safety Compliance Certification Label Payload The combined maximum allowable weight of cargo and passengers that the truck is designed to carry Payload is GVWR minus the Base Curb Weight NOTATION EXPLANATION Hazard notations appear in various locations in this publication Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe Notes are used to help emphasize areas of procedural importance and provide helpful suggestions The following definitions explain the use of these notations as they appear throughout this guide INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY Indicates a procedure practice or hint which is important to highlight MN 746 8 Load Controller Dual Installation Diagram fig 1 Adapter 1 Analog dual gauge B 7 gt M oN Power yellow wire Adapter 2 Adapter ais Fuse adapter or gs Female 25 gt Fuse spades Fuse box Adapter 3 V x3 S Female spade K or P K N
11. m state to state Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages The above limitation or exclusion may not apply to you There are no warranties expressed or implied including any implied warranties of merchantability and fitness which extend beyond this warranty period There are no warranties that extend beyond the description on the face hereof Seller disclaims the implied warranty of merchantability Dated proof of purchase required Air Lift 10007 Lifetime Limited LoadController Dual 2 Year Limited RideControl Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller Il 2 Year Limited SlamAir Lifetime Limited SmartAir 2 Year Limited AirCell Lifetime Limited Wireless AIR 2 Year Limited Air Lift Performance 1 Year Limited WirelessONE 2 Year Limited LoadController Single 2 Year Limited Other Accessories 2 Year Limited formerly SuperDuty formerly LifeStyle amp Performance and EasyStreet 15 fF Load Controller Dual Replacement Information If you need replacement parts contact the local dealer or call Air Lift customer service at 800 248 0892 Most pa
12. mplate drill holes and mount the compressor using the black mounting hardware that comes in the box containing the compressor fig 11 Frame Floor pan fig 12 Attach the compressor ground wire to one of the mounting screws fig 1 AIR LINE AND POWER WIRES ROUTING FOR THE STANDARD DUTY COMPRESSOR 1 Push the air line onto the barb fitting on the compressor Make sure the air line covers all barbs A small amount of water or lubricant and pushing with a slight circular motion will ease installation fig 13 Air line Power red wires Barbed fitting check valve MN 746 Load Controller Dual MN 746 a AIR LINE AND POWER WIRE ROUTING FOR THE HEAVY DUTY COMPRESSOR 1 Remove the nut from the leader hose and install over air line from check valve assembly 2 Push the air line from the check valve assembly into the barbed fitting on the compressor leader hose 3 Slide the nut over the fitting and tighten securely fig 14 Filter Compression fitting Check valves Leader hose Butt connector yellow Power red wire Ground fig 14 A2 heavy duty compressor 4 Route the harness to the compressor a b Use existing grommets in the floorboard or firewall to route the harness from the cab to the frame mounted compressor In some cases a hole may have to be drilled to allow access for the harness Drill a 1
13. ning out these problems usually requires an increase in pressure E 8 Sway body roll fe 13 8 14 Load Controller Dual Guidelines for adding air 1 2 3 Bottoming out Start with the vehicle level or slightly above When in doubt always add air For motorhomes start with 50 100 PSI in the rear because it can be safely assumed that it is heavily loaded If the front of the vehicle dives while braking increase the pressure in the front air bags if equipped If it is ever suspected that the air bags have bottomed out increase the pressure fig 20 Adjust the pressure up and down to find the best ride If the vehicle rocks and rolls adjust the air pressure to reduce movement It may be necessary to maintain different pressures on each side of the vehicle Loads such as water fuel and appliances will cause the vehicle to be heavier on one side fig 21 much as a 50 PSI difference is not uncommon Unlevel MN 746 Load Controller Dual LF Warranty and Returns Policy MN 746 Air Lift Company warrants its products for the time periods listed below to the original retail purchaser against manufacturing defects when used on catalog listed applications on cars vans light trucks and motorhomes under normal operating conditions for as long as Air Lift manufactures the product The warra
14. nty does not apply to products that have been improperly applied improperly installed used in racing or off road applications used for commercial purposes or which have not been maintained in accordance with installation instructions furnished with all products The consumer will be responsible for removing labor charges the defective product from the vehicle and returning it transportation costs prepaid to the dealer from which it was purchased or to Air Lift Company for verification Air Lift will repair or replace at its option defective products or components A minimum 10 00 shipping and handling charge will apply to all warranty claims Before returning any defective product you must call Air Lift at 800 248 0892 in the U S and Canada elsewhere 517 322 2144 for a Returned Materials Authorization RMA number Returns can be sent to Air Lift Company 2727 Snow Road Lansing MI 48917 Product failures resulting from abnormal use or misuse are excluded from this warranty The loss of use of the product loss of time inconvenience commercial loss or consequential damages is not covered The consumer is responsible for installation reinstallation labor charges of the product Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured This warranty gives you specific legal rights and you may also have other rights that vary fro
15. or Connect adapter to HOT side of the fuse With the ignition on the compressor will turn on and fill the system to 10 PSI before shutting off 7 Press the off on button to inflate both air springs and use the small deflate button to adjust the pressure Inflate to 30 PSI 20 PSI for Air Lift 1000 kits Check all fittings and inflation valve cores with a solution of 1 5 dish soap to 4 5 water in a spray bottle for leaks IMPORTANT If the compressor runs continually or often then there is a leak Disconnect the compressor at the fuse box and test for leaks with a soapy water solution NEVER RUN THE COMPRESSOR LONGER THAN FOUR MINUTES CONTINUOUSLY ALLOW AT LEAST FIVE MINUTES FOR COOL DOWN BEFORE STARTING THE COMPRESSOR AGAIN MN 746 Load Controller Dual 8 Product Use Information Frequently asked questions MN 746 Q Will installing air springs increase the weight ratings of a vehicle No Adding air springs will not change the weight ratings GAWR GCWR and or GVWR of a vehicle Exceeding the GVWR is dangerous and voids the Air Lift warranty Is it necessary to keep air in the air springs at all time and how much pressure will they need The minimum air pressure should be maintained at all times The minimum air pressure keeps the air spring in shape ensuring that it will move throughout its travel without rubbing or wearing on itself Is it necessary to add a compressor system to the ai
16. r springs No Air pressure can be adjusted with any type of compressor as long as it can produce sufficient pressure to service the springs Even a bicycle tire pump can be used but it s a lot of work How long should air springs last If the air springs are properly installed and maintained they can last indefinitely Will raising the vehicle on a hoist for service work damage the air springs No The vehicle can be lifted on a hoist for short term service work such as tire rotation or oil changes However if the vehicle will be on the hoist for a prolonged period of time support the axle with jack stands in order to take the tension off of the air springs Tuning the air pressure Pressure determination comes down to three things level vehicle ride comfort and stability 1 Level vehicle If the vehicle s headlights are shining into the trees or the vehicle is leaning to one side then it is not level fig 17 Raise the air pressure to correct either of these problems and level the vehicle Ride comfort If the vehicle has a rough and harsh ride it may be due to either too much pressure or not enough fig 18 Try different pressures to determine the best ride comfort Stability Stability translates into safety and should be the priority meaning the driver may need to sacrifice a perfectly level and comfortable ride Stability issues include roll control bounce dive during braking and sponginess fig 19 Tu
17. rts are immediately available and can be shipped the same day Contact Air Lift Company customer service at 800 248 0892 first if Parts are missing from the kit Need technical assistance on installation or operation Broken or defective parts in the kit Wrong parts in the kit Have a warranty claim or question Contact the retailer where the kit was purchased If itis necessary to return or exchange the kit for any reason f there is a problem with shipping if shipped from the retailer If there is a problem with the price Contact Information If you have any questions comments or need technical assistance contact our customer service department by calling 800 248 0892 Monday through Friday For calls from outside the USA or Canada our local number is 517 322 2144 For inquiries by mail our address is PO Box 80167 Lansing MI 48908 0167 Our shipping address for returns is 2727 Snow Road Lansing MI 48917 You may also contact us anytime by e mail at sales or on the web at www airliftcompany com 16 MN 746 Need Help Contact our customer service department by calling 800 248 0892 Monday through Friday For calls from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airliftcompany com warranty KF Thank you for purchasing Air Lift products the professional installer s choice Air Lift Company 2727 Snow
18. stall the air spring kit first per the instructions provided with the air spring Kit fig 10 Compressor side Gray Black ground 1 Install the gauge pod figs 4 5 amp 6 Select a convenient mounting location that has a sturdy rigid surface The bottom edge of the dash on either side of the steering wheel is a good location Attach the gauge pod to the selected location with the black self tapping Screws Optional dash mounting bracket and hardware also included fig 7 2 Connect the harness to the gauge pod a Connect the color coded wires to the gauge harness as shown in the attached schematic fig 2 b Connect the low pressure switch assemblies as shown in the attached schematic fig 2 Do not connect the power wire at this time d The wiring harness also connects the gauge pod to the low pressure sensor assembly The low pressure sensor protects the air springs from failure resulting from low pressure in the unloaded condition This sensor is preset to maintain a MINIMUM pressure of 5 PSI in the air springs unless the setting was changed in the Getting Started section The sensor measures the pressure in each spring and turns on the compressor if the pressure falls below the set PSI e Screw ground eyelet to firewall or other electrical ground in the cab The sensor should be located under the dash inside the vehicle and secured with the provided tie straps
19. ter so that all moisture can easily drain Please also remember To avoid high heat environments To avoid mounting the compressor under the hood To check to be sure the compressor harness 2 will reach the compressor and connect to harness 1 The compressor can be mounted in any position vertical upside down sideways etc please refer to the instruction manual GETTING STARTED This part of the installation should be done after the air spring kit is installed If you have any questions please call Air Lift customer service at 800 248 0892 If you are adding this control system to an Air Lift LoadLifter 5000 application then no modifications to the low pressure sensor are necessary If you are adding this control system to an Air Lift 1000 or Ride Control application and if your specific application requires a minimum of 10 PSI then it will be necessary to adjust the low pressure sensor to 10 PSI To increase the pressure in the low pressure sensor remove the rubber plug with pliers fig 8 Using an allen wrench turn the screw clockwise 4 4 turns fig 9 Push the rubber plug back into the top of the low pressure sensor Proceed with the step by step installation instructions rubber o Turn allen screw 4 14 turns clockwise fig 8 8 MN 746 Load Controller Dual LF NOTE NOTE MN 746 STEP BY STEP INSTALLATION We recommend that you in
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