ARB Air Locker Operating and Service Manual
Contents
1. ing Service Operat No liability is assumed for damages resulting in the use of the information contained herein ARB Air Locker locking differentials and Air Locker are trademarks of ARB Corporation Limited Other product names used herein are for identification purposes only and may be trademarks of their respective owners How the ARB Air Locker Works _ Why Lock a Diff The History of Air Locker 1 The Air Locker Concept 2 Operating Instructions General Air Locker Use 4 On Highway Use 5 Off Road Use 6 Safety Considerations 8 ARB Not Just Air Lockers 10 Service Guide Lubricants Specifications 12 Regular Service Schedule 13 In Field Service Repair 13 Trouble Shooting A Genuine Air Locker Accessories 18 Warranty 19 LOCKING DIFFERENTIALS How the Air Locker Works Why Lock a Diff The History of Air Locker exhilarating adventures one could have But as any four wheeler can tell you spinning your wheels and getting stuck leads to nothing but frustration Often you know you have the right vehicle to take on the most extreme terrain yet still you find that it baulks at the slightest of obstacles losing traction at the most inappropriate times leaving you stranded and embarrassed F our wheel driving across rough terrain can lead to some of the most The problem is quite simple one or more of your vehic2. Internal mechanical damage Air line blocked Compressor malfunction Electrical fault Seized solenoid Dump valve if fitted is slowing actuation Dump valve if fitted is seized and passing air into the differential housing Inspect differential unit for damage or lodged foreign objects Repair or replace as necessary Inspect full length of air line for kinks pinched sections or presence of oil or foreign matter in the line which may restrict air flow Make sure the compressor is functioning and is capable of supplying at least 85 psi Check for blown fuse or relay on com pressor Check all electrical connections to switch and solenoid Solenoid should instantly open allowing free flow of air when switch is activated Replace solenoid if faulty Slight actuation delays are normal when dump valves are fitted If delay is too long then dump valve should be replaced Replace dump valve raue Sooty Symptom Air Locker will not disengage when switched OFF Possible Cause s Wheels under torque Electrical fault Internal damage Solenoid seized Solenoid exhaust port is blocked Solution s With the Air Locker switch turned OFF and the wheels turned straight slowly move the vehicle back and forth until the unit unlocks Inspect all electrical connections for a possible short If it is necessary to move the vehicle you can manually disconnect the a
3. wiring procedure and diagrams Clean bulb socket and all terminal connections Replace bulb if necessary Carefully remove switch cover and replace in correct position Air Locker Heavy Duty Air Line Kit Part No HDAL This optional Aeroquip reinforced air line and adapter kit installs directly to your existing Air Locker differential Air Locker Bulkhead Fitting Kit Part No 170102 Its a good idea to carry spare parts for any vehicle accessory when challenging the unknown perils of the bush ARB recommends you also take along a spare bulkhead fitting kit Air Locker Switch Bracket Kit Part No ALSB1 2 3 ARB s genuine Air Locker switch plates are powder coated black for a durable finish and are a perfect fit for your Air Locker actuation switch or your ARB air compressor isolator switch Kits come with either 1 2 or 3 switch brackets ALSB1 ALSB2 or ALSB3 Genuine Air Locker Accessories Air Locker Air Line Service Kit Part No ASK001 This convenient kit contains everything you ll need to repair a damaged air line ARB Air Compressor Kit Part No RDCKA The ARB air compressor kit was developed specifically for use with ARB s Air Locker range The kit comes complete with 12v air compressor with automatic pressure switch 12v 30amp relay compressor mounting bracket and hardware on off switch amp plug in Air Locker wiring loom Air Compressor Pump Up Kit Part No PUKT Use your
4. ARB air compressor to inflate your tyres air mattresses water toys etc by installing a pump up kit This kit is specially designed to fit ARB s compressor and installs easily Warranty ARB Air Locker Limited Warranty ARB s Air Locker locking differentials are warranted to be free from defects in materials and workmanship for a period of twenty four 24 months or 40 000 kilometers 24 000 miles whichever occurs first from the date of first retail purchase Except where otherwise implied by the Trade Practices Act ARB s obligation under this warranty shall be limited to repairing or replacing or crediting at ARB s option any part found to be defective ARB does not warrant or make any representations outside of those implied by the Trade Practices Act concerning its ARB Air Locker locking differentials when i The product s are not installed used and maintained in strict accordance primarily with the manufacturer s instructions and second with all good installation and maintenance practices of the automotive industry ii The product s are installed in any vehicle which is used in competition of any type iii The product s are installed in any vehicle fitted with tyres which have diameters in excess of 5 greater than that vehicle s factory standard diameter tyre iv The product s are installed in any vehicle which has undergone drive line modifications resulting in an increase of torque
5. and or power in excess of that vehicle s factory standard except where such modifications have been approved by ARB When settlement is sought under the terms of this warranty a claim shall be made as follows i The ARB Air Locker locking differential which the customer claims to be defective is to be returned along with all other supplied accessories and hardware accompanied by the proof of purchase to an authorised ARB Air Locker distributor ii The authorised ARB Air Locker distributor shall contact ARB to have the claim approved prior to any settlement The benefits conferred by this war ranty are in addition to the rights and remedies which the customer has under the Trade Practices Act and similar state and territory laws in respect of the product by an authorised ARB Air Locker locking differentials distributor or any other person Copyright by ARB Corporation Limited Head Office ARB Corporation Limited 42 44 Garden Street Kilsyth Victoria 3137 AUSTRALIA Tel 61 3 9761 6622 Fax 61 3 9761 6807 Web www arb com au Email E Enquiries within Australia T sales arb com au International enquiries exports arb com au North Central amp South American Enquiry Contras Air Locker Inc l 20 South Spokane Street Seattle Washington 981 34 USA Tel 206 264 1669 Fax 206 264 1670 Part No 210200 Printed in Australia
6. ring gear a system sometimes referred to as a spool the vehicle maintains maximum possible traction at all times Operating Instructions General Air Locker Use Air Locker differentials can be engaged and disengaged at the flip of a switch When you need the extra traction simply turn on your compressor approach the difficult terrain and press the Air Locker switch even if you are still moving Once you are past your trouble spot flip the switch back again and the Air Locker will disengage and return your vehicle to normal operation Push On Illuminated With Dash Lights Illuminated When Switch Is Activated Push Off when to use your Air Locker and what to expect from your vehicle while using it is indeed a skill and requires a level of understanding and experience before you can safely and effectively get the most out of your vehicle N Ithough operating a switch may require very little skill knowing Never engage the Air Locker during cornering or when the wheels are spinning as this could damage the locking mechanism Just as you wouldn t put your vehicle in gear without using the clutch the gears in your Air Locker need to be doing roughly the same speed before you engage them as well Also remember that your Air Locker doesn t necessarily engage instantaneously when your vehicle is stationary You may need to roll the vehicle a little bit until the teeth of the locking mechanism can fa
7. aking unless necessary will help your tyres bite into a loose surface Operating instructions Safety Considerations PLEASE READ THOROUGHLY Your ARB Air Locker was engineered as a safety enhancement to the use of your vehicle While ensuring you have the same road handling ability that your vehicle came with it also gives you that extra ability to get safely through the situations which may otherwise leave you and your passengers stranded amp all with only the flip of a switch Air Locker differentials are simple to use and very safe when used correctly however a few points should be understood and followed to ensure the least risk to your vehicle and occupants E Driving on high traction surfaces e g dry pavement concrete bitumen sandstone etc with your Air Lockers engaged locked is very harsh on drive train components and could result in damage to your vehicle Lock your Air Locker s only when necessary to overcome limited traction EB Having your Air Locker s engaged will affect your steering even if you only have one in the rear axle Make sure you take the time to get to know the effects of driving with a locked differential before you attempt any use which may put you your passengers or your vehicle at risk El Air Locker switches should always be located within easy reach of the driver but they must be located where they will not accidentally be operated by the driver passengers or loose objec
8. can render it impossible to keep four wheels on the ground Locking your Air Locker s can often be your only alternative to a winch or a tow Plan your path across such obstacles so you don t compromise your vehicle s center of gravity and roll over Use low range and idle throttle where possible and proceed slowly DRIVING UPHILL Try to align the vehicle straight up the incline and keep the rear Air Locker engaged to maintain a constant push Maintain a very light approach to throttle use AIM FOR ZERO WHEEL SPIN Use of the front Air Locker in this situation is greatly dependent on the nature of the terrain and mostly dependent on the feel DRIVING DOWNHILL Again as with all hill driving straight down the hill is preferable to descent at an angle Always use engine braking if possible over foot braking Engage the rear Air Locker once you start moving Use of the front Air Locker can be of great benefit when engine braking downhill as it prevents the sudden surge felt when one wheel breaks traction but driver preference must still make the final decision DRIVING OFF CAMBER When traversing an incline sideways on a surface with low or unpredictable traction a situation best avoided if possible leave both Air Lockers disengaged Having both wheels driven together may promote slipping where an unlocked axle should allow each wheel to find its deepest traction point Limiting your throttle to a low range idle and not br
9. damaged fittings ferrules etc Trim or replace any damaged mating sections of tubing Replace all pneumatic seals Replace dump valve Compressor runs continuously ONLY when Air Locker is Leak in air system Inspect air line and all air connections for leaks using a soap and water mixture Pressure cutout switch malfunction Seized solenoid switched ON Air leak inside differential Remove filler plug and listen for leaking housing or bubbling when air is switched ON Inspect bulkhead fitting and transfer tube inside housing and replace repair leaking component s and seals as necessary Dump valve if fitted is Replace dump valve seized and passing air into the differential housing Compressor ALWAYS runs Compressor malfunction Make sure compressor is working continuously correctly and is capable of supplying at least 85 psi Inspect and replace cutout switch if necessary Replace solenoid Compressor runs continuously and blows air through solenoid only when Air Locker is switched OFF Solenoid connected backwards Connect the compressor to port 1 and the Air Locker air line to port 2 Refer to fitting instructions No illumination occurs in switches when headlights are turned ON Illumination terminal not correctly connected to dashboard Illumination bulb s blown or not functioning Switch cover installed upside down Refer to fitting instructions for correct
10. et of vehicle movement regardless of vehicle speed Damaged ring gear Inspect and replace if necessary Noise from differential while decelerating from any speed Damaged pinion bearing Inspect and replace if necessary Metallic particles are present in differential oil Carrier bearings damaged Differential gear worn or damaged Foreign object loose in differential housing Inspect and replace damaged bearings Refer to your vehicle service manual Inspect differential gears and ring and pinion set for signs of wear or damage and replace if necessary Inspect all differential components for damage and replace as necessary row Snow Symptom Excessive oil visible at solenoid exhaust port Please Note Some oil mist around the solenoid is perfectly normal Possible Cause s Pneumatic seals damaged Pneumatic seal running surfaces worn or damaged Misaligned or damaged seal housing Foreign particles present in differential oil Solution s Replace all pneumatic seals Disassemble differential and inspect all sealing surfaces for scoring Repair or replace as necessary Inspect seal housing for damage and make sure seal housing is fitted according to the supplied installation instructions Disassemble and thoroughly clean all components Air Locker engages slowly or will not engage at all when switch is activated
11. ials Driving force applied to the ring gear rotates the differential center but does not directly drive the axle shafts Small bevel gears known as pinions rotate freely on the cross shaft s which are securely fixed to the body of the differential The axle shafts are joined by a splined coupling to the two larger bevel gears known as side gears which are supported by the differential body in constant mesh with the pinions When one axle rotates inside the differential it drives the pinion gears which in turn drives the opposite axle only in the opposite direction of rotation This is called differential action Under normal circumstances this action benefits your vehicle by allowing the outside wheel to spin faster than the inside wheel when turning an absolute necessity for highway driving Unfortunately differential action only works so long as both wheels have full traction with the road Once one wheel loses grip e g one wheel is on a slippery surface or suspended in mid air the differential transfers its driving force to the wheel that is easiest to turn i e the slipping wheel and therefore all the driving torque is lost The advantage of the ARB Air Locker lies in the pneumatically operated locking system inside the body of the differential which when activated prevents the differential gears from rotating and therefore preventing differential action between the axles With both wheels tied directly to the rotation of the
12. ir line from the compressor Inspect differential unit for damage or lodged foreign objects Repair or replace as necessary Replace solenoid Remove any obstruction from the exhaust port located in the middle of the round knob on the top of the solenoid Air Locker disengages slowly when switched OFF Air line blocked Inspect full length of air line for kinks pinched sections or presence of foreign matter in the line which may restrict air flow Check for oil in air line Air Locker engages when switch is in the OFF position and disengages when switch is turned ON Switch cover installed upside down Carefully remove switch cover and replace in correct position Leakage in bulkhead fitting Fitting too loose to form seal Worn or damaged sealing components Inspect and appropriately tighten all compression fittings Replace all damaged fittings ferrules etc Trim or replace any damaged mating sections of tubing Leakage at solenoid Fitting too loose or too tight to form adequate seal Solenoid body damaged i e cracked cross threaded Inspect and if necessary apply thread sealant to fittings and retighten Replace solenoid row Snow Symptom Leakage inside differential housing Possible Cause s Worn or damaged sealing components Pneumatic seals damaged Dump valve if fitted is seized Solution s Replace all
13. le s wheels is losing traction and your highway minded factory differential center is directing ALL of your vehicle s power to those spinning wheels Newer vehicles with limited slip differentials LSDs may offer some improvement over standard diffs but more often you ll find the slipping is not as limited as you need to keep you going Automatic locking differentials also have their disadvantages they can be very noisy when disengaging and will upset the on highway driving characteristics of your vehicle ARB has been challenging conventional thinking of off road equipment designs for over 25 years and the ARB Air Locker has been a success story from the start Born of the need to get 100 traction when you need it without sacrificing any of your vehicle s highway driving performance ARB Air Lockers employ the same air compressor commonly used by four wheel drivers to control their tyre pressures and to activate and deactivate a solid and durable lock inside the differential center This gives you the traction you need when you need it all at the flip of a switch all within the safety and comfort of the driver s seat 2 JJ b ar 5 gt pe L u 4 de ur y Ter P a f gt x m Mi THe Air Latk r Um Standard Open Differential ARB s Air Locker Locking Differential The Air Locker Concept hen unlocked ARB Air Lockers operate much the same as Ne open different
14. level with filler plug hole or 75 000km 46 600 miles See Recommended Lubricants Specifications of highway only use If the axle installation angle has been modified i e the vehicle has been raised or is used for lengthy steep incline climbs a standpipe may be needed to modify the filler level of the housing After every 12 000km Check differential oil level and inspect for leaks 7 460 miles After each use in water Change differential oil to maintain viscosity and to and or mud flush out any trapped water mud or other foreign particles Clean or replace breather After each use in dense bush Inspect all sections of exposed air line for abrasion and or protruding rocks or cuts After each heavy use Change differential oil to maintain viscosity and to i e competition use flush out any foreign particles Every 6 months maximum Operate the Air Locker to ensure it is in good working condition Check air system for deposits of moisture condensation or oil Flush clean with compressed air if necessary Clean or replace axle breather NOTE In addition to the service schedule above always adhere to all service guidelines set forth in your vehicle manufacturer s service manual In Field Service Repair ARB Air Lockers are engineered to give you years of trouble free use however harsh terrain can sometimes find a way of taking its toll often when you least expect it Just as you carry s
15. ll into mesh When disengaging your Air Locker always remember that the teeth of the locking mechanism cannot disengage while under torque Your Air Locker was designed to stay locked under the harshest of loads and therefore even with the switch disengaged you will sometimes need to untorque your axle by rolling your vehicle forward or backward slightly before the locking mechanism will unlock On Highway Use ARB s Air Locker range of locking differentials offers one big advantage that few of its competitors can even come close to on the highway you won t even know it s there With your Air Locker disengaged switched OFF it behaves and performs no different than any regular open differential that comes standard with most vehicles from the manufacturer There is no disconcerting jolt or special driving techniques to get used to as there is with most other lockers on the market erat instructions gradual corners oversteering out of tight corners and often spinning its wheels rather than moving at all Engaging your Air Locker will help you get rolling through the trouble spots Some operators prefer to leave them engaged while driving in snow but remember engaging your Air Locker will change the way your steering behaves especially when using a front Air Locker Take it slow at first and give yourself time to get used to it before you try anything too challenging l n the snow your vehicle can easily lose tracti
16. on understeering into When not in use simply keep your Air Locker s as well as your air compressor switched OFF ARB s own range of off road special purpose air compressors come with an isolating switch to keep your air compressor from charging up when you don t need it We highly recommend an isolating switch for all highway use vehicles Off Road Use DRIVING ON LEVEL HIGH TRACTION SURFACES As long as all wheels can stay in contact with a high traction surface locking a differential is not necessary and could place undue load on your drive train Cornering on high traction terrain with your differential locked especially the front is never recommended as it creates high torque load across your axle shafts and CVs In these cases it is preferable to leave your Air Lockers unlocked until the need for them arises DRIVING ON LEVEL LOW TRACTION TERRAIN Heavy traction loss can affect overall vehicle control with open or unlocked differentials as traction is randomly transferred from side to side across the axle Off road driving control will be greatly enhanced through mud snow water loose gravel and other forms of low traction surfaces when one or both Air Lockers are engaged Gentle throttle and smooth methodical steering will keep the vehicle moving steadily where you point it erating Instmuelions DRIVING ON UNEVEN TERRAIN Rock crawling ditch crossing and other highly challenging forms of off road driving
17. pare tyres fuses drive belts etc you should also consider packing an air line repair kit part no ASK001 and some cable ties along with the necessary tools to ensure you are prepared for any unforseen damage to your air line Refer to page 18 for our listing of Genuine Air Locker Accessories Trouble Shooting Symptom Running noise from differential ONLY WHEN CORNERING Possible Cause s Differential gear s damaged Foreign object particles present in differential oil Wheel bearing s damaged Solution s Inspect all differential gears and internal running surfaces for signs of damage and replace as necessary Inspect all differential components for damage and repair or replace as necessary Refer to your vehicle service manual Running noise from differential WHEN MOVING STRAIGHT AS WELL AS WHEN CORNERING Carrier bearings damaged or worn out Incorrect backlash setup between ring and pinion gears Ring and pinion set damaged Differential oil level too low Wheel bearing s damaged Inspect and replace damaged bearings Refer to your vehicle service manual Adjust ring and pinion backlash Refer to your vehicle service manual for correct backlash setup procedure Inspect and replace if necessary Fill oil level until level with filler plug hole Refer to your vehicle service manual Intermittent noise from differential occurring approx once per meter 3 fe
18. s Alongside Air Lockers ARB has been manufacturing a complete range of quality reliable and practical 4x4 accessories for over 25 years which we proudly export along with the Air Locker to over 50 countries Here a selection of some of our most popular products on Type of Use Recommended Lubricant Normal Typical Use Shell Diff Oil SAE 90 highway and light to medium off road use Mobil Mobilube GX90 between 12 and 100 C 10 to 212 F Heavy Off Road Use Shell Spirax HD 85W 140 high horsepower high torque use Mobil Mobilube GX140 between 9 and 100 C 16 to 212 F High Temperature Desert Use Shell Spirax S 80W 140 mainly off road use Mobil Mobilube SHC 80W 140 between 30 and 100 C 22 to 212 F Low Temperature Winter Use Shell Spirax S 75W 90 mainly off road use Mobil Mobilube SHC 75W 90 between 48 and 100 C 54 to 212 F To find other lubricants which are equivalent to the examples above please contact your authorised ARB LS Nas Alp bocker Seres Huida Recommended Regular Service Schedule Frequency of Service Description of Service Check or Operation After the first 2 500km Change differential oil Clean or replace axle breather 1 500 miles of use and after NOTE Always fill until almost level with filler plug each subsequent 50 000km hole manually rotate differential several times then 31 000 miles of off road use fill again until
19. ts moving within the cabin Accidental locking or unlocking could result in loss of control of the vehicle erating tutius E If used an isolating switch ensures that the air compressor will not start unnecessarily To avoid risk of unintentional Air Locker engagement always leave your Air Locker actuator switch in the OFF position when not in use and therefore never use the isolator switch to engage the Air Locker This will prevent your Air Locker from engaging when using the compressor for other purposes such as inflating tyres E Although ARB Air Lockers are engineered tough they should never be engaged during wheel spin i e a situation when one wheel is spinning faster than the other on the same axle This could cause undue wear or damage to your Air Locker or other drive train components as a result of the shock created when both wheels are suddenly forced to turn at the same speed Be sure you are stopped or driving in a straight line without any acceleration or deceleration i e do not have either the accel erator or the brakes pressed or engaged while locking the Air Locker EZ To reduce the risk of vehicle drive train damage and or the loss of control of your vehicle always reduce speed when your Air Locker s are engaged or anytime you are negotiating rough terrain Slow and methodical off road driving will prolong the life of all drive train components elcome to the world of ARB 4x4 Accessorie
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