ARC4000e 4 wheel compressor system w / 4 way Ride Pro controller

Transcription

1 350 S. St. Charles St. Jasper, In Ph Fax on the internet: ARC4000e 4 wheel compressor system w / 4 way Ride Pro controller 1 ARC5001 Compressor 1 CON6000 RidePro e control panel (includes the following) 4-DIG1051 Sending units 4-FIT7014 1/8" airline bulkhead connector 1-A207 Sending unit mount 1- WIR8000 Wiring harness for CON ARV2500 RidePro air valve assemblies 1 F gallon tank 2 ARL ft. roll of 1/4 DOT airline 1 PRE psi pressure switch 2 ARL1000 1/8 airline (25 feet) air valve to sending unit 1 FIT7500 Compressor tee for pressure switch 4 FIT4201 1/4"npt x 1/4"tube elbow fitting 7 FIT4000 1/4"npt x 1/4" tube straight fitting supply to air valve/delivery to air spring 4 FIT2000 1/8 npt x 1/8 tube straight fitting air valve to sending unit 1 FIT7004 1/4"npt plug to plug unused supply port 1 FIT7001 1/4 npt close nipple to connect air valve assemblies 1 Compressor and Air Tank Template 1

2 350 S. St. Charles St. Jasper, In Ph Fax on the internet: ARC4000e Compressor System Instructions These are some general guidelines to follow when installing your new air control system. Depending on the vehicle there are many different ways to plumb the system. Start out by planning a lay out of where you want everything to be mounted. Typically we try to keep the compressor, solenoids, tank, and sending units in a central location, but they can be separated to suit your needs. Mounting the Compressor Remove the negative battery cable before beginning installation. All of our compressors are sealed for moisture and dust resistance so they can be mounted anywhere on the vehicle. Although it is best to mount it in a place out of direct contact with rain and snow. It is OK to mount it underneath the vehicle but keep it inside the frame rails away from water and debris thrown off the tire. This is a dry compressor; therefore it is maintenance free and can be mounted in any position. It is best if mounted to something solid to reduce vibration and noise. If mounting it to sheet metal or the bed or a truck use sound deadening material between the compressor and the mounting surface. Use the rubber grommets supplied on the feet of the compressor to reduce vibration. A template is supplied to aid in drilling the holes. Check template with compressor before drilling the holes A main power wire of 10ga. or larger will be needed to supply the compressor. It will attach to one of the spades on the 150 psi pressure switch. The other spade will attach to the Red wire on the compressor. A 20 amp inline fuse is supplied and should be installed between the battery and pressure switch as close to the battery as possible. The black wire should be attached to a clean ground, usually the frame. Mounting the Air Tank The air tank can be mounted anywhere on the vehicle in any position. A template is supplied to aid in drilling the holes. Check the template with the tank before drilling the holes. If your air system is used frequently you may need want to remove the tank once a season to drain any excessive accumulation of water. 2

3 Mounting the RidePro Air Valves The valves, like the compressor, are sealed and can be mounted in the same locations. Although if the vehicle will be exposed to freezing temperatures it is a good idea to mount them in the engine bay if possible to reduce the possibility of freezing. They can be mounted in any position. Try to mount the valves higher than the tank to reduce condensation build up. Attach the ground strap to a good, clean ground (preferably the frame). The exhaust port will be left open. The valve is held closed with the pressure in the tank. If tank pressure drops below air spring pressure they will equalize deflating all 4 air springs. Mounting the Sending Units Thread sending units into the bulkhead. They should seal without using any thread sealant. Too much thread sealant could cause a faulty ground resulting in an erratic reading on the display. The sending units are grounded through their mount. It may be necessary to attach a ground wire from the mount to a good ground. (It is best to run this ground wire directly to the negative post on the battery). If mounting them close to the compressor it may be necessary to isolate the sending units from the frame in a way so the ground must travel through the ground wire directly to the negative post on the battery. Routing the Airline and Fittings Make all airline cuts with a razor or tubing cutter. It must be clean and straight or it will not seal. Most fittings are DOT approved push-to-connect style. They are very simple to use and are reusable. Firmly push the airline into the fitting to attach. To release the airline pull the collar on the fitting back towards the fitting and pull the airline out. Use thread sealant on all fittings. Do not over tighten the fittings. This could result in breaking the fitting or damaging the air spring. All of our airlines are DOT approved so they are very strong but not idiot proof. Keep away from any sharp edges. When passing through a hole in the frame use a grommet. Keep away from intense heat including mufflers and exhaust manifolds. Use zip ties or other fasteners to secure the airline. 3

4 ! " #$ ## 4

5 Installation of the RidePro e Control Panel and ECU Installation notes: Disconnect the negative battery cable. Before starting the installation turn the DIP switches to the OFF position. If this is not done the vehicle may fully deflate when the key is turned on. The ECU should be mounted inside the vehicle to avoid moisture and to be accessible to make programming changes. Do not mount the ECU box in the engine bay or underneath the car, it is not weather proof and must be mounted in a dry area inside the vehicle. It is also best if mounted as far away from the compressor as possible. The electric motor in the compressor can cause interferences that may affect the air pressure pre-set function. Do not plug in the ECU until all the wiring is complete. The air pressure sending units must be grounded to function properly. This can be accomplished through a metal mounting bracket or by attaching a ground wire to the main body of the sensor. Too much Teflon between the sending unit and the bulkhead can also attribute to a poor ground. It may also be necessary to run the ground wire directly to the negative side of the battery post. The control panel display unit can be flush mounted or surface mounted in any location inside the vehicle or it can be left unmounted. It is supplied with 6 ft. leads to the computer box. 12 ft. leads are available from the factory if desired. DO NOT lengthen or shorten these leads call the factory for a longer harness. The control panel is an LCD display. The pressure reading may not be legible if mounted at an extreme angle to the driver. You may want to power up the system temporarily to insure you are able to see the display properly in your selected mounting location. If used with an extremely fast solenoid system and you are experiencing problems with the presets, additional tuning may be required. Restricting the exhaust ports or decreasing the airflow will help. Solid core spark plug wire will permanently damage any sensitive electronic equipment. Use proper RFI suppressor plug wires that are in good condition. 5

6 Wiring the ECU Connector # 1 Power harness Connect green/black stripe to illumination Connect yellow to ignition Connect black to directly to ground of battery Connect red to directly to battery 12v positive Connector # 2 Sensor harness Connect green/white wire to left front pressure sensor Connect brown wire to right front pressure sensor Connect purple wire to left rear pressure sensor Connect red/white wire to right rear pressure sensor Connector # 3 Solenoid harness NOTE: This harness will have a weatherpak connector on it that will plug in to our existing RidePro solenoids. There will be no further connections necessary. If you have another brand or type of solenoid, please refer to the connection instructions below for proper connection. Front Harness Connect orange or brown wire to left UP solenoid Connect red or white wire to left DOWN solenoid Connect black right UP solenoid Connect blue to right DOWN solenoid Rear Harness Connect orange or brown wire to left UP solenoid Connect red or white wire to left DOWN solenoid Connect black wire to right UP solenoid Connect blue wire to right DOWN solenoid NOTE FOR EXISTING RIDEPRO INSTALLATIONS: If installing the weatherpak connectors OR using the wiring instructions above DOES NOT achieve proper orientations of the switches, you may have to swap the airline connection positions at the air valve to ensure that the control panel switches are coordinated with the correct air springs. 6

7 Control Panel and ECU Wiring Diagram 7

8 How to code the key fob transmitter to the ECU: If you have chosen the remote control option for your Ride Pro E system you will have to code the key fobs to the ECU to allow communication between the ECU and the key fobs. 1. Make sure the antenna is plugged into the ECU. 2. With the ignition switch OFF, press the ECU programming button on the ECU 3 times. The programming LED on the ECU should then be lit solidly. 3. Within 25 seconds press the left front (LF) button on one key fob then press the left front (LF) on the other key fob with a short 2-3 second pause between key fobs. Up to 3 key fobs are possible. 4. When the LED on the ECU goes out the key fob will be ready for use. How to program the air pressure presets: To Program air pressure preset #1: This is the default setting that will be engaged every time the vehicle is started. It can also be engaged via the [optional] key fob transmitter by placing the slide switch in the up position and pressing the 5 th button on the side of the key fob. It is recommended that this air pressure be adjusted to the highway ride height of the vehicle. 1. Place the DIP-switches located on the side of the computer box in the OFF (UP) position 2. Turn ignition ON 3. Set desired air pressure of the vehicle with main control panel switches 4. Press the program button, located on the side of the ECU 6 times, then led on the ECU will then flash. 5. Press the program button one additional time (7 th ) and hold it in for 4 seconds. The display on the control panel will then flash slowly 4 times to indicate the programming was successful. (This last step can also be done with the optional remote control. Instead of pressing the program button the 7 th time, just set the slide switch on the side of the remote to the UP position and press the #5 button of the side of the remote.) To Program air pressure setting #2: This air pressure preset is only accessible from the optional remote control keyfob transmitter. This air pressure setting is typically adjusted to set the vehicle at a lowered height for parking. This does not necessarily need to be 0 psi. Set it for the highest psi possible in which the suspension is bottomed out. This will help the vehicle rise a little faster. 1. Place the DIP-switches located on the side of the computer box in the OFF (UP) position 2.Turn ignition ON 3. Set desired air pressure of the vehicle with main control panel switches 4. Press the program button, located on the side of the computer box 6 times the led beside the program button will then flash. 5. Set the slide switch on the side of the remote to the DOWN position and press the #5 button on the side of the remote to enter the #2 setting into the remote control system. The main control panel display will flash quickly four times to indicate remote control setting #2 was successful. After ALL programming is complete, return the DIP-switches to the ON position to activate the air pressure presets. NOTE: The vehicle will return to the #1 air pressure preset every time the vehicle is started. If you DO NOT wish to use the air pressure preset feature, simply leave the DIP switches in the OFF [UP] position. 8

9 How to operate the RidePro E system The main control panel display contains the switches for inflating or deflating the individual air springs. The position of the switches corresponds to the position of the air springs in your vehicle. NOTE: The control panel is functional ONLY when the key is ON. It is disabled when the key is OFF. The optional remote control system is functional ONLY when the key is OFF. Control Panel: Top Left Switch: Controls left front ride height UP or DOWN Indicates Air Pressure of left front air bag Top Right Switch: Controls right front ride height UP or DOWN Indicates Air Pressure of right front air bag Bottom Left Switch: Controls left rear ride height UP or DOWN Indicates Air Pressure of left rear air bag Bottom Right Switch: Controls right rear ride height UP or DOWN Indicates Air Pressure of right rear air bag Remote Key Fob: (Optional) Button 1 (LF): Controls left front ride height UP or DOWN Button 2 (RF): Controls right front ride height UP or DOWN Button 3 (LR): Controls left rear ride height UP or DOWN Button 4 (RR): Controls right rear ride height UP or DOWN Button 5 (side of transmitter): Activates air pressure presets Slide Switch UP: Controls buttons 1-4 ride height UP and controls level #1 setting Slide Switch DOWN: Controls buttons 1-4 ride height DOWN and controls level # 2 setting Note: The Remote control will only function with the key in the OFF position. 9

10 Compressor System Troubleshooting Guide Problem Symptom Possible Cause Possible Solution Compressor will not turn on. Faulty pressure switch. Faulty relay. Note: Some systems will not use a relay Blown fuse One air spring leaks down over a period of time. All 4 air springs leak down over a period of time. 12 volts are measured on the red wire at the compressor and it still will not turn on. The compressor will not turn on when the pressure in the tank drops below 135 psi or will not shut off after reaching 150psi and there is 12v at the switch. Compressor will not turn on and there is 12v at the small red wire on the relay but not at the white wire. Compressor will not turn on and 12v are measured on the battery side of the fuse but not on the comp. side. Use soapy water in a spray bottle to help find leaks. You can also switch the delivery lines at the valve to determine weather the leak is at the valve or at the air spring. Usually the air springs with more pressure will start to drop first. 1. Poor compressor ground. 2. Faulty connection between battery and compressor. 3. Bad compressor. 1. Faulty connection. 2. Low battery voltage. 3. Bad pressure switch. (This can be tested by jumping the spades on the switch. If the comp. then kicks on the switch is bad. Also if it continues to run past 150psi it is bad.) Faulty connection or low battery voltage. 1. Low battery voltage. 2. Faulty connection. The spades at the pressure switch sometimes become loose. (Low voltage will cause a high amp. draw.) 4. Wrong size fuse. The Thomas 327 needs a 20amp and the Viair 400 needs a 30 amp. 1. Leak at one of the fittings or airlines. 2. Exhaust valve is leaking. Usually due to dirt stuck on the seat. 3. Air spring is leaking. (Check the fittings first, it is almost always the problem.) There is a leak in the supply side of the system. This could be at the comp., tank, or supply ports on the valve. 1. Make sure there is a clean connection directly to the frame. 2. Even though there is 12v at the compressor there may not be sufficient amperage. 3. Replace the compressor. 1. Check all connections between the battery and ground on the comp. 2. Low voltage will cause the comp. to draw more amperage. This will normally blow the fuse first. Replace or recharge battery. 3. Replace switch. Test battery and check all connections between the battery and comp. ground. Replace relay. 1. Test battery. 2. Fix connections or tighten spades. 3. Replace fuse 1. Tighten fitting or reseal with more thread sealant. Replace fitting if needed. 2. Cycle that valve up and down numerous times. Blow valve out with shop compressor. 3. Replace air spring. Fix leak. 10

11 Ride Pro e Troubleshooting Guide Problem Symptoms Possible Cause Possible Solution Vehicle will not achieve air pressure target on 1 st try. (It may take 2 or 3 attempts.) The air pressure reading is inaccurate or erratic. Air pressure preset and/or remote function does not work. Remote control does not work. Vehicle overshoots the target air pressure. Display does not turn off when the vehicle is turned off. Switch function and air pressure reading seem reversed. Control panel switches do not activate the correct air spring. Control panel switches activate the correct air spring, but the air pressures read the wrong air spring. When you first start the vehicle (or activate remote control), the vehicle goes up but stops at an air pressure that is lower than the programmed target. After the compressor runs to refill tank (and additional re-starts are made) the target pressure may be achieved. Inaccurate pressure readings may also cause poor performance of the air pressure preset. When you start the vehicle or activate the remote control, nothing happens Display does not turn off when the vehicle is turned off. Also the air pressure preset may not function properly. The top switches activate the rear air springs; the bottom switches activate the front air springs. Example: left front switch actuates the right rear air spring. Example: activating the right front air spring changes the left rear pressure. 1. Air tank is too small to allow vehicle to come up to target air pressure without refilling tank. 2. There may be a leak at the air tank or fittings that allows the tank pressure to leak down. 3. Vehicle is being fully deflated. 1. Poor ground connection to the pressure sending units. 2. Poor ground at the ECU. 3. Too much thread sealant on the sending units. One or both DIP switches are turned OFF. 1. Remote control antenna is not plugged in or is plugged into the wrong terminal. 2. Remote is not coded to the ECU. 3. Yellow wire is connected to a constant 12v. A poor ground to the air pressure sending unit will cause the computer to see bad input. The yellow and/or red wires in the power harness are hooked up incorrectly. The weatherpak connectors going to the solenoids are reversed. Airlines are connected differently from the wiring harness. Air pressure sensor airlines and/or wiring harness is connected to the wrong ports or terminals. 1. Install larger air tank. Minimum size of 3 gallons is recommended for most vehicles. Heavy vehicles may require an even larger tank. 2. Find and repair the leak. 3. Deflating the vehicle only until the suspension bottoms out saves air. 1. Install a dedicated ground wire from sensor mount and ECU directly to the battery. 2. You may also need to isolate the sending unit mount from the frame to eliminate any electrical interferences. Make sure DIP switches located on the ECU are ON. This is the DOWN position. 1. Check antenna connection. It should be plugged into the blue connector. 2. Refer to the instructions to code the remote to the ECU. 3. Connect to key hot. Run a direct ground wire from the sensor mounting to the negative post of the battery. Check these 2 connections to make sure they are not reversed or otherwise installed incorrectly. Switch the weatherpak cables at the solenoids. Switch airlines to appropriate air valve ports. Example: press the top right control panel switch to activate the air valve connect the right front airline to that air valve port. Review the pressure sensor airlines and wiring to achieve proper connection order. 11