Air Commander Part No

Transcription

1 EASYSTEET Air Commander Part No MN-510 (06506) EC 5206 Please read these instructions completely before proceeding with installation The oil level in the compressor must be checked BEFOE running the engine or compressor. Failure to do so will result in a faulty compressor and a void warranty. Front View Side View Important Warranty Information 1. If the compressor or engine is run without having oil in the compressor, the warranty is void. 2. If the belt is not properly installed, or if the belt does not have proper tension, the warranty is void. 3. Failure to use included installation components properly voids the warranty. 4. Failure to check proper oil level and conditions voids the warranty. 5. This compressor must be used in an air compressor application only, not an air conditioning application. No freon is required. Hardware Item P/N Description Qty. A Alternator/Compressor Pulley 1 B Idler Shaft 1 C Idler Pulley Assembly 1 D Compressor Bracket 1 E Lower Compressor Spacer 1 F V-Belt 1 G Computer Bracket 1 H eservoir Bracket 1 I /8"-16 x 1 Bolt GD 5 3 J /8"-16 x 2.75 Bolt 1 K /8"-16 x 1.5 Bolt GD 5 1 L /8" Flatwasher 6 M /8" Lockwasher 3 Item P/N Description Qty. N /8"-16 Nylock Nut GD 8 1 O M x 40 mm FHSCS 1 P /4"-20 x 2 Bolt GD 2 1 Q /4"-20 x 1 Bolt /16" x 5 /8" x.032 Flatwasher 10 S /4" - 20 Nylock Nut 4 T Computer Spacer 1 U Self-Tapper 2 V Zip Tie 3 W Hose Clamp Worm 1 /4" 2 X Engine Coolant eservoir 1 Y Wire Clip 1 Z Compressor Support Bracket 1 1

2 IMPOTANT: Always keep safety in mind when working on your vehicle. I. Assembling the Compressor Clamp 1. Using the four bolts supplied with the clutch, attach the clutch to the compressor (Figure 1). Tighten the bolts securely. NOTE: Make sure that the wire is on the bottom-side of the compressor. 2. Place the compressor drive pulley over the clutch and align the keyway. Attach the pulley using the provided hardware. Tighten securely to the shaft (Figure 1). 3. oute the wire through the wire clip (Y) (Figure 1). Attach the wire clip using a bolt (I) and a flat washer (L). Check Oil Figure 1 II. Preparing the Vehicle 1. Disconnect your battery. 2. emove the rear coolant reservoir flange nut. 3. emove all three computer bolts and lift the computer out of the way (Figure 3). 4. emove the two remaining coolant flange nuts. etain one of the flange nuts for later use. 5. Disconnect the overflow hose from the radiator and remove the reservoir from the vehicle. 6. emove the radiator overflow hose and clamp from the reservoir and retain for installation of the new coolant reservoir (X). 7. emove the front and rear coolant reservoir mounting studs and discard. Figure 2 Figure 3 Figure 4 2

3 III. Mounting the Computer 1. Mount the computer bracket (G) to the remaining coolant reservoir mounting stud, with the flat side of the bracket pointing toward the engine. Tighten down using O.E.M nut. 2. Using the middle tab on the computer, mount the computer to the bracket (G) with bolt (Q), two flatwashers () and nut (S). Leave loose at this time. 3. Push the computer back as far as possible. NOTE: There must be at least 5 between the computer mounting tab and the battery terminals (Figure 4). Hole in OEM Computer Bracket Computer Bracket Fender-well T P S Pre-drilled Hole in Fender-well 4. Using the front computer mounting tab as your pilot hole, drill a 1 /4" hole through the fender-well (Figure 4). Figure 5 NOTE: Make sure the tire has clearance to the fender-well or has been removed beforehand. 5. Place a bolt (P) and a flatwasher () on the under-side of the fender-well. On the top-side of the fender-well, place a flatwasher (), spacer (T), flatwasher (), computer tab, flatwasher () and nut (S) (Figure 5). 6. Mount the computer to the spacer assembly. 7. Tighten all of the computer mounting hardware securely at this time. Completed installation of the computer bracket is shown in figure 6. Figure 6 IV. Installing the Pulley 1. Disconnect the red positive alternator cable and the plug connector from the rear of the alternator. 2. Loosen the serpentine belt and remove it from the alternator pulley. 3. emove all three alternator bolts and retain for later use. 4. emove the alternator from the vehicle. 5. While the alternator is out of the vehicle, cut the air conditioner return line bracket off of the air conditioner canister and discard (Figure 7). Figure 7 6. emove O.E.M. alternator-drive pulley and replace with alternator/compressor combo-drive pulley (A). 7. e-install the alternator and insert only the driver-side alternator bolt. etain the passenger-side bolts for installation of the compressor bracket (Figure 8). 8. Do not re-install the serpentine belt at this time. 9. Do not re-install the alternator cable at this time. Figure 8 3

4 V. Installing the Compressor Bracket 1. Bend the air conditioner return line out of the way of the compressor area until it is in line with the computer (Figure 6). 2. emove and discard the wiring loom bracket from the alternator (Figure 9). 3. Attach the compressor bracket (D) to the passenger-side of the alternator by installing a countersunk bolt (O) into the wiring loom boss with the spacer (E) between the compressor bracket (D) and the alternator bracket. Leave loose at this time. 4. e-install the two remaining, previously removed alternator bolts. Put the bolts through the two side-mounting tabs on the compressor bracket (D) and into the front and rear of the alternator bracket (Figure 10). Figure 9 5. Tighten all hardware securely. Begin with the countersunk bolt and tighten the two remaining bolts making sure that the bracket lines up parallel to the alternator and the engine (Figure 11). 6. e-install the serpentine belt. V. Installing the Compressor 1. Install the compressor to the mounting bracket using two bolts (I), two flatwashers (L) and two lockwashers (M) in the top and one bolt (K), one flatwasher (L) and one lockwasher (M) in the bottom. Leave the bolts loose. Figure Align the compressor drive pulley to the combo pulley and tighten the compressor bolts. NOTE: The use of a straight-edge may be helpful when aligning the compressor drive pulley with the combo pulley (Figure 12). 3. Install the compressor support bracket (Z) by first removing the OEM A/C bolt. Next, attach the support bracket with the compressor mounting bolt. eattach the OEM A/C bolt so that it runs through the support bracket and into its stock location (Figure 13). VI. Installing the V-Belt and Idler Assembly Figure Install the V-belt (F) onto the combo pulley and compressor drive pulley. 2. Install the idler assembly to the compressor bracket using bolt (J), flatwasher (L), idler pulley (C), idler shaft (B), compressor bracket slot, flatwasher (L) and nylock nut (N) (Figure 12). Do not tighten at this time. NOTE: The hardware must be installed in the above order to ensure proper operation. 3. Adjust the tension by sliding the idler assembly down in the slot on the compressor bracket until the V-belt is firm. 4. Tighten the nylock nut. Figure 12 4

5 VII. Mounting the Coolant eservoir 1. Place the coolant reservoir bracket (H) in between the battery and the computer. Push the bracket as close as possible to the computer. 2. Using the bracket as a template, drill two holes in the fenderwell. NOTE: Make sure the tire has clearance to the fender-well or has been removed beforehand. 3. Using two bolts (Q), two nylock nuts (S), and four flatwashers (), affix the bracket to the fender-well. 4. Mount the coolant reservoir (X) to the bracket using two 1 /4" selftapping screws (U) (Figure 14). 5. e-attach the radiator overflow hose to the radiator. oute the hose to the bottom of the reservoir and clamp the hose to the barb fittings on the reservoir and radiator with the supplied hose clamps (W). Compressor Mounting Bolt Figure 13 OEM A/C Bolt VIII. Connecting the Alternator Cable 1. oute the alternator cable through the under-side of the compressor bracket (Figure 15) and re-install at the rear of the alternator. NOTE: Be sure to tie all cables and hoses away from the pulleys and other moving parts using the supplied nylon tie straps (V). 2. econnect the battery making sure that battery cables clear the engine-driven compressor pulley. 3. Start the engine and observe the belt pulley for alignment and tension. NOTE: Do not engage the clutch at this time. Figure 14 Figure 15 Thank you for purchasing Air Lift Products Mailing Address: Street Address: AI LIFT COMPANY AI LIFT COMPANY P.O. Box Snow d. Lansing, MI Lansing, MI Local Phone: (517) Fax: (517) For Technical Assistance call EASYSTEET The Choice of the Professional Installer Printed in the USA