Docstoc

Figure 1 Figure 2 Figure 3

Document Sample
Figure 1 Figure 2 Figure 3 Powered By Docstoc
					                                                                                                        MN-219
                                                                                                        (03509)
                                                                            BY                          ECN1558




                                                     1. Jack up rear of vehicle or raise on hoist. Support frame
                              REMOVE RUBBER
                                BUMP STOP               with safety stands. Remove lower shock absorber
                                                        attaching bolts.

                                                     2. Lower axle or raise body or vehicle until suspension is
                                                        fully extended. CAUTION: Observe tension on brake
                                                        line - do not strain. Remove coil springs noting location
                                                        of the end of the coil spring in the lower spring seat.

                                                     3. Using a 3/4” drill enlarge the diameter of the hole in the
                                                        lower spring seat to 3/4”. Remove all burrs and sharp
                                                        edges (Figure 2).

                                                     4. Using a socket and extension, remove the rubber bump
                                                        stop from the upper spring seat and discard (Figure 1).
                   Figure 1
                                                     5. Insert air cylinder into coil spring with stem at bottom
                                                        (Figure 3).

                                                     6. Raise the axle or lower the body to install coil spring into
                                                        spring seats and rotate to proper location. Attach lower
                                                        shock absorber attaching bolts. Torque to 25 ft. lbs.

                                                     7. Install air line as detailed on pages 2 and 3. A tee air line
                                                        installation is recommended unless weight in vehicle
 INCREASE HOLE
DIAMETER TO 3/4"
                                                        varies form one side to the other and unequal pressures
                                                        are needed to level load (or compensate for axle torque
                                                        transfer in racing application). Dual air lines are used in
                                                        this case. Proceed with TEE AIR LINE ROUTING or
                                                        DUAL AIR LINE ROUTING

                                                     8. Inflate cylinders to 25 lbs. air pressure. Test for air leaks
                                                        by applying a liquid soap and water solution to all valve
                   Figure 2                             cores, fittings and connections.

                                                     9. Lower vehicle to the ground. Read Maintenance &
                                                        Operation Tips for proper care of your air cylinders.
                                                        Recheck air pressure after 24 hours. A 2-4 p.s.i. loss
                                                        after initial installation is normal. If pressure has
                                                        dropped more than 5 lbs. re-test for leaks with soapy
                                                        water solution.
                                          Fig.3 MN 138




                   Figure 3
                                                       Tee air line installation recommended unless weight in vehicle varies
                                                       from one side to the other and unequal pressures are needed to level
               A                      C                the load. Dual air lines are used in this case.

                                                                              TEE AIR LINE ROUTING

                                                       TO PREVENT AIR LINE FROM MELTING, KEEP IT AT LEAST
                         B                             EIGHT INCHES FROM EXHAUST SYSTEM.

                                                       A. Locate desired tee location on the frame rail or cross member.

                                                       B. Determine and cut adequate length of air line to reach from tee to
                                                          left and right side on air cylinders.
    Use this procedure for all air line connections:
    A. Slide air line clamp onto the air line          CAUTION: LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT
    B.       Push the air line over the barbed         ANY STRAIN ON FITTING DURING AXLE MOTIONS.
       stem.
    C.       Compress the ears on the air line         C. Slide air line clamp onto the air line. Push the air line over one side
       clamp with pliers and slide it forward to
       fully cover the barbed section.
                                                          of the tee until all the barbs are covered. Repeat procedure for
                                                          other leg of tee.

                                                       D. With pliers slide the air line clamp forward until it fully covers the
                                                          barbed section. Repeat for other leg of tee (Figure 4).

                                                       E. Route along cross member and either lower control arm or upper
                                                          spring seat to air cylinder.

                                                       F. Insert air line through lower spring seat then slide on air line clamp.

                                                       G. Push the air line onto the stem, covering all the barbs. With pliers
                                                          slide the air line clamp upward until it fully covers the barbed
                                                          section (Figure 5).

                                                       H. Push the remaining air line over the last fitting on tee and route
                                                          along frame to desired inflation valve location (Figure 6). Attach
                                                          with plastic straps or wire.
                     Figure 5
                                                       I. Select a location for inflation valve in the gas cap well, the trunk,
                                                          rear bumper, fender flange or behind the license plate, assuring
                                                          that the valve will be protected and accessible with an air hose
                                                          (Figure 6).

                                                       J. Drill a 5/16” hole for inflation valve and mount as in illustration
                                                          (Figure 8). Rubber washer is for outside weather seal.

                                                       K. Slide air line clamp over the air line. Push air line onto fitting
                                                          covering all barbs, with pliers slide the air line clamp forward until
                                                          it fully covers the barbed section (Figure 6).

                                                       L. Raise axle or lower body until air cylinders lightly touch the upper
                                                          and lower spring seat.

                                                       M. Check TAILPIPE clearance and insure that it is at least 2-3 inches
                                                          from air cylinder. If necessary, loosen clamps and rotate or move
                                                          to obtain additional clearance. If heat shield is provided, install it.

                                                          NOTE: Attach shock absorbers if removed earlier in the
                                                          installation.
                     Figure 6                          N. Continue with step 8, page 1.

                                                          DO NOT INFLATE AIR CYLINDERS BEFORE READING
                                                          MAINTENANCE/OPERATION TIPS.


2
                                                             DUAL AIR LINE ROUTING

                                             TO PREVENT AIR LINE FROM MELTING, KEEP IT AT
                                             LEAST EIGHT INCHES FROM EXHAUST SYSTEM.

                                             A. Select a location for the inflation valves in the rocker
                                                panel flange, or rear bumper, assuring that each valve
                                                will be protected and accessible with an air hose
                                                (Figure 9).
               Figure 7
                                             B. Determine and cut adequate length of air line to reach
                                                from valve location to left side air cylinder.

                                             CAUTION: LEAVE SUFFICIENT AIR LINE SLACK TO
                                             PREVENT ANY STRAIN ON VALVE STEM DURING
                                             NORMAL AXLE MOTIONS.

                                             C. Insert the air line through the lower spring seat.
        Vehicle Bumper
           or Body                Air Line   D. Slide air line clamp onto the cut air line. Push the air
                   Hex Nut                      line onto the stem, covering all the barbed section.
    Flat                                        With pliers slide the air line clamp forward until it fully
                                 Air Line
   Washer                         Clamp         covers barbed section (Figure 5).
                         Inflation
                          Valve              E. Repeat process for right side.
                     Lock                    F. Drill 5/16” hole for inflating valves and mount as
          Rubber    Washer
                                                illustrated. Rubber washer is for outside weather seal
          Washer                                (Figure 8).
Hex Nut
                                             G. Route air line along control arm and frame to inflation
                                                valve location and cut off excess air line.
               Figure 8
                                             H. Slide air line clamp onto the air line and push the air line
                                                over the fitting, covering all the barbs. With pliers slide
                                                the air line clamp forward until it fully covers the barbed
                                                section.

                                             I. Raise axle or lower body until air cylinders lightly touch
                                                the upper and lower spring seat.

                                             J. Check TAILPIPE clearance and insure that it is at least
                                                2-3 inches from air cylinders. If necessary, loosen
                                                clamps and rotate or move to obtain additional
                                                clearance. If heat shields are supplied, install them.

                                                NOTE: Attach shock absorbers if removed earlier in the
             Option 1                           installation.
             Option 2
                                             K. Continue with step 8, page 1.

                                                DO NOT INFLATE AIR CYLINDERS BEFORE
                                                READING MAINTENANCE/OPERATION TIPS.
               Figure 9




                                                                                                               3
    FAILURE TO MAINTAIN MINIMUM PRESSURE WILL VOID THE WARRANTY


          MINIMUM AIR PRESSURE                                   MAXIMUM AIR PRESSURE
                 5 P.S.I.                                               25 P.S.I.
     MAINTENANCE TIPS:
     1. Check pressure weekly!
     2. Always maintain at least 5 p.s.i. air pressure to prevent chafing or coil pinch.
     3. If you develop an air leak in the system, use a soapy/water solution to check all air line connections
        and the valve core before removing cylinder.
     OPERATING TIPS:
     1. Inflate your air springs to 25 p.s.i. before adding the payload. This will allow the air cylinder to
        properly mesh with the coil spring. After vehicle is loaded, adjust your air pressure (down) to level
        the vehicle and for ride comfort.
     2. When you are carrying a payload it will be helpful to increase the tire inflation pressure in proportion
        to any overload condition. We recommend a 2 p.s.i. increase above normal (not to exceed tire
        manufacturers maximum) for each 100 lbs. additional load on the axle.


                                          Thank you for purchasing Air Lift Products

                                                    AIR LIFT COMPANY
                                                       P.O. BOX 80167
                                                    Lansing, MI 48908-0167


          FOR TECHNICAL ASSISTANCE CALL 1-800-248-0892
    Caution: DO NOT EXCEED THE VEHICLE MANUFACTURERS MAXIMUM GROSS VEHICLE WEIGHT RATING.

                                                                                             Printed in the USA
4
                                                                                                                            MN-126
                                                                                                  by                        (10006)
                                                                                                                           NPR 2858

Multiple Applications – See special notes for your particular vehicle.
NOTE: If your vehicle is equipped with vibration dampers between the turns of the coil, it is necessary that these be
removed before installing the air springs. Their function will be replaced by the air spring.
Some mid-size GM vehicles have a solid cup located on the lower spring seat which will not allow the air line to exit the
coil. It is necessary to removed this cup before installing the air spring.

                                                                I. Preparing the Vehicle
                                                                Before beginning the installation, check the clearance from coil
                                                                spring to exhaust. It is common in your application for the exhaust
                                                                to be very close to the coil. If there is not more than 2", you will
                                                                need to move the pipe for additional clearance.
                                                                 1. Jack up rear of vehicle or raise on hoist. Support frame with
                                                                    safety stands. Lower axle or raise body of vehicle until
                                                                    suspension is fully extended.
                                                                 2. Install heat shield kits. Separate instructions are included in
                                                                    heat shield package.

                                                                 3. Remove plastic cap from barbed stem on end of cylinder.
Figure 1a                      Figure 1b                            Exhaust the air from the cylinder by rolling it up toward barbed
                                                                    stem. Replace cap on stem to hold flat shape.

                                                                 4. If necessary, additional clearance between the coil turns may
                                                                     be obtained by removing the shock absorbers from the lower
                                                                     shock mountings and lowering the suspension an additional
             Top of Spring Seat
                                                                     one to two inches.
                                                                     CAUTION: Observe tension on brake air line—do not strain.

                                            Trim out 1"
                                                                II. Installing the Air Cylinder
                                            of rubber boot       1. For installing the air cylinder in 1991 and up Crown Victorias,
                                                                    Mercury Grand Marquis, 2000 Suburbans, 4DR-4WD
                                                                    Tahoes–Yukons use step 1b.
                                                                     a. Insert flattened air cylinder into coil spring through lowest
                                                                        opening with stem at the bottom (Figure 1a).
                                                                     b. IMPORTANT: For Suburbans, Tahoes and Yukons it will
Figure 2                                                                be necessary to trim the rubber isolater at the top for the
                                                                        vavle stem clearance (Figure 2). Insert flattened air
                                                                        cylinder into coil spring through lowest opening with the
                                                                        stem at the top (Figure 1b).

                                                                 2. Push the cylinder up within the coil by hand or with a blunt
                                                                    instrument such as a spoon-type tire iron.
                                                                 3. When the cylinder is completely within the coil, remove the
                                                                    cap and allow the cylinder to assume its “as molded” shape.

                                                                 4. For inserting the protector in 1991 and up Crown Victorias,
                                                                    Mercury Grand Marquis, 2000 Suburbans, 4DR-4WD
                                                                    Tahoes–Yukons use step 4b.
                                                                     a. Push cylinder to the top of the coil and insert protector on
 G.M. 1973 & up vehicles or         G.M. 1962 & 1972                    top of lower spring seat (See Figures 3a and 3b).
 Ford 1979-1990 vehicles air    vehicles or Ford 1966-1978
       line behind axle         vehicles air line behind axle        b. Push cylinder to the bottom of the coil and insert protector
Figure 3a                      Figure 3b                                at the top (See Figure 4 ).
                                                                     1
                                                     III. Installing the Air Line
                                                     Install air line as detailed on pages 2 and 3. A tee air line installation
                                                     is recommended unless weight in vehicle varies from one side to
                                                     the other and unequal pressures are needed to level the load (or
                                                     compensate for axle torque transfer in racing application). Dual air
                                                     lines are used in this case.

                                                                           TEE AIR LINE ROUTING
                                                     CAUTION: To prevent air line from melting, keep it at least 8" from
  1991 and up Ford Crown Victoria
                                                     exhaust system.
1991 and up Mercury Grand Marquis
2K 4DR 4WD Tahoes–Yukons and 2K                       1. Locate desired tee location on the frame rail or cross member.
     Suburban with coil springs                          Determine and cut adequate length of air line to reach from
Figure 4                                                 tee to left and right side on air cylinders.

            A                       C                     CAUTION: Leave sufficient air line slack to prevent any strain
                                                          on fitting during axle motions.

                                                      2. Slide air line clamp onto the air line.
                      B                               3. Push the air line over one side of the tee until all the barbs are
                                                         covered. With a pair of pliers, slide the air line clamp forward
                                                         until it fully covers the barbed section. Repeat entire procedure
                                                         for other leg of tee (Figure 5).

 Use this procedure for all air line connections:     4. Route along cross member and either lower control arm or
 A. Slide air line clamp onto the air line.              upper spring seat to air cylinder.
 B. Push air line over the barbed stem.
 C. Compress the ears on the air line clamp with
    pliers and slide it foward to fully covers the    5. Insert air line through spring seat and spacers.
    barbed section.

Figure 5                                              6. Push the air line onto the stem, covering all the barbs (Figure
                                                         6). With the pliers, slide the air line clamp upward until it fully
                                                         covers the barbed section.

                                                      7. Push the remaining air line over the last fitting on tee and
                                                         route along frame to desired inflation valve location (Figure
                                                         6). Attach with plastic straps or wire.

                                                      8. Select a location for inflation valve in the gas cap well, the
                                                         trunk, rear bumper, fender flange or behind license plate,
                                                         insuring that the valve will be protected and accessible with
                                                         an air hose.

                                                      9. Drill 5/16 " hole for inflation valve and mount as in illustration
                                                         (Figure 8). Rubber washer is for outside weather seal.

                                                     10. Slide air line clamp over the air line. Push air line onto fitting
Figure 6                                                 covering all barbs, with pliers slide the air line clamp forward
                                                         until it fully covers the barbed section (Figure 9).

                                                     11. Raise axle or lower body until air cylinders lightly touch upper
                                                         spring seat and lower spacers.

                                                     12. Check tail pipe clearance and insure that it is at least 2-3 inches
                                                         from air cylinder. If necessary, loosen clamps and rotate or
                                                         move to obtain additional clearance. If heat shield is provided,
                                                         install. Attach shock absorbers if removed earlier in the
                                                         installation.




Figure 7
                                                           2
     CAUTION: Do not inflate air cylinders before reading the
     maintenance and operation section.

 13. Continue on with Section IV, Completing the Installation.                          Vehicle Bumper
                                                                                           or Body                Air Line
                     DUAL AIR LINE ROUTING                                                         Hex Nut
CAUTION: To prevent air line from melting, keep it at least 8" from                 Flat                         Air Line
exhaust system.                                                                    Washer                         Clamp
 1. Select a location for the inflation valves in the rocker panel flange,                               Inflation
                                                                                                          Valve
    or rear bumper, assuring that each valve will be protected and
    accessible with an air hose (Figure 9).                                                          Lock
                                                                                          Rubber    Washer
 2. Determine and cut adequate length of air line to reach from valve                     Washer
    location to left side air cylinder.                                       Hex Nut
     CAUTION: Leave sufficient air line slack to prevent any strain
     on fitting during axle motions.

 3. Insert the air line through the spring seat and spacer.                   Figure 8

 4. Slide air clamp onto the cut air line.

 5. Push the air line onto the stem, covering all the barbed section
    (Figure 6). With pliers slide the air line clamp forward until it fully
    covers barbed section.

 6. Repeat process for right side.

 7. Drill 5/16 " hole for inflating valves and mount as illustrated. Rubber
    washer is for outside weather seal (Figure 8).

 8. Route air line along control arm and frame to inflation valve
    location and cut off excess.

 9. Slide a clamp onto the air line and push the air line over the
    fitting, covering all the barbs. With pliers slide the air line clamp
    forward until if fully covers the barbed section (Figure 9).

10. Raise axle or lower body until air cylinders lightly touch upper
    spring seat and lower spacers.

11. Check tail pipe clearance and insure that it is at least 2-3 inches Figure 9
    from air cylinders. If necessary, loosen clamps and rotate or move
    to obtain additional clearance. If heat shields are supplied, install
    them. Attach shock absorbers if removed earlier in the installation.
     CAUTION: Do not inflate air cylinders before reading the
     maintenance and operation section.

12. Continue on with Section IV, Completing the Installation.




                                                                                              Option 1
                                                                                              Option 2




                                                                              Figure 10
                                                                3
IV. Completing the Installation
Prior to following these steps, review the Maintenance and Operations section below.
 1. Inflate cylinders to 35 lbs air pressure. Test for air leaks by applying a liquid solution of 1/5 dish soap to 4/5 water to
    all valve cores, fittings and connections.

 2. Lower vehicle to the ground. Read Maintenance/Operation Tips for proper care of your air cylinders.

 3. Recheck air pressure after 24 hours. A 2-4 p.s.i. loss after initial installation is normal. If pressure has dropped more
    than 5 lbs. retest for leaks with a soapy/water solution.




Maintenance and Operations
            MINIMUM AIR PRESSURE                                              MAXIMUM AIR PRESSURE
                           5 psi                                                           25 psi
By following these steps, vehicle owners should obtain the longest life and best results from their air springs.

Maintenance Tips:
 1. Check the air pressure in the air springs weekly.

 2. Always maintain at least the 5 p.s.i. air pressure to prevent chafing or coil pinch.

 3. If you develop a leak in the system, use a soapy/water solution to check all air line connections and the valve core
    before removing the cylinder.

Operating Tips:
 1. Inflate your air springs to 35 p.si. before adding the payload. This will allow the air cylinder to properly mesh with the
    coil spring. After vehicle is loaded, adjust your air pressure (down) to level the vehicle and for ride comfort.

 2. When you are carrying a payload it will be helpful to increase the tire inflation pressure in proportion to any overload
    condition. We recommend a 2 p.s.i. increase above normal (not to exceed tire manufacturers maximum) for each
    100 lbs. additional load on the axle.


CAUTION: Do not exceed the vehicle manufacturers maximum gross vehicle weight rating.

CAUTION: Failure to maintain minmum pressure will void the warranty.



                                               Thank you for purchasing Air Lift Products

                                          Mailing Address:                               Street Address:
                                          AIR LIFT COMPANY                               AIR LIFT COMPANY
                                          P.O. Box 80167                                 2710 Snow Rd.
                                          Lansing, MI 48908-0167                         Lansing, MI 48917
                                                               Local Phone: (517) 322-2144
                                                                   Fax: (517) 322-0240

                        For Technical Assistance call 1-800-248-0892
           “The Choice of the Professional Installer”
                                                                                                              Printed in the USA
                                                              4

				
DOCUMENT INFO