Air Commander Part No , with air Part No , without air

Transcription

1 EASYSTREET Air Commander Part No , with air Part No , without air Please read these instructions completely before proceeding with installation. The oil level in the compressor must be checked BEFORE running the engine or compressor. Failure to do so will result in a faulty compressor and a void warranty. Front View Side View MN-494 (02204) ECN 3827 Important Warranty Information 1. If the compressor or engine is run without having oil in the compressor, then the warranty is void. 2. If the belt is misinstalled or the belt does not have the proper tension, then the warranty is void. 3. Failure to use included installation components properly voids the warranty. 4. Failure to check proper oil level and conditions will void the warranty. 5. This compressor must only be used in an air compressor application only, not an air conditioning application. No freon is required. Item Description Part Number Qty. A Compressor B Serpentine Belt (with air) C Serpentine Belt (without air) D Alternator Pulley E Clutch/Pulley Assembly F Idler/Pulley Assembly G Overflow Reservoir H Coelescing Filter I Inlet Filter J Leader Hose K Computer Bracket L Compressor Plate M Coolant Reservoir Bracket N Upper Bracket O Lower Left Bracket P Lower Right Bracket Q Air Filter Bracket R Brass Cross Bracket S Compressor Fitting T Compressor Sleeve Insert U O-ring V 1 /2" NPT Check Valve W 1 /4" NPT Relief Valve X p.s.i. Pressure Switch Y 1 /2" NPTM x 1 /2" Tube Straight Z 1 /2" NPTM x 1 /4" NPTF Bushing AA 1 /2" Brass Cross BB Plug CC 1 /2" NPTM x 1 /8" NPTF Bushing DD 1 /2" NPTF Coupling Installation Components Item Description Part Number Qty. EE 1 /2" Street Tee FF 3 /8"-16 x 3 /4" Bolt GG 3 /8" Flat Washer HH 3 /8"-16 x 1 Carriage Bolt II 3 /8"-16 x 7 /8" Bolt JJ 3 /8" Lock Washer KK 3 /8"-16 Hex Nut LL 8mm-1.25 x 25mm Bolt MM 8mm Flat Washer NN 8mm Lock Washer OO Frame Clamp PP 1 /4"-20 x.75" Bolt QQ Self Tapper RR 5 /16" Flat Washer SS x 3 /8" Machine Screw TT 1 /4"-20 Kep Nut UU 1 /4" Hose Clamp Worm VV 20 amp AGC Fuse WW Red 16 Gauge Wire ' XX ATC/ATO Fuse Tap In YY Mini Fuse Adapter ZZ Butt Connector AB 1 /4" Female Terminal AC AGC Fuse Tap In AD 3 /16" Female Terminal AE Thread Sealant AF 1 /2" Nylon Hose ' AG Hose Cutter AH Oil Dipstick AI Pipe Nipple

2 J JJ GG DD L Y S S DD A I Y EE AI V Y Y Z H W Figure 1 X R AA BB To Keyed Power Source CC To Air Tank Y 2 II

3 NOTE: This compressor will mount on the right (passenger) side of the engine. It may be necessary to relocate or remove the air conditioning lines. If the oil is low in the compressor, use Polyol Ester (P.O.E.) P.A.G. oil and fill to specified amount. I. Assembling the Compressor 1. Attach the clutch to the compressor using the four bolts that come in the box with the clutch (Figure 2). Tighten the bolts securely. NOTE: Make sure that the wire is at the bottom right hand side of the compressor. 2. Place the pulley (E) over the clutch and align the keyway. Attach the pulley (E) using the provided hardware. Tighten securely to the shaft (Figure 4). Figure 2 3. Attach the small clamp that came with the clutch using bolt (FF) and flat washer (GG). Route the wire through the clamp (Figure 3). 4. Attach the plate (L) to the left side of the compressor (engine side) using bolts (II), lock washers (JJ), and flat washers (GG). Be sure to insert the carriage bolt (HH) before bolting the plate down (Figure 5). NOTE: The long tab at the bottom of the bracket faces the rear of the compressor (Figure 5). 5. Remove the small bolt on the open side of the compressor above the line clamp previously installed and check the oil level in the compressor with the supplied dipstick (AH). The oil level should be from 1 to 1 1 /4" on the dipstick. The compressor should have a total of 8 fl. oz. (237 ml). Use Polyol Ester (P.O.E.) P.A.G. oil only. Attach the plug and tighten. Figure 3 Figure 4 Figure 5 3

4 II. Preparing the Vehicle 1. Remove the belt, belt tensioner, positive battery cable, back and side alternator bolts, computer and bracket, and radiator overflow. 2. It will be necessary to slightly bend the inner fender to obtain adequate clearance for the compressor. Use a pry bar or a 2 x 4 and pry using the frame (Figure 6). Figure 6 3. Unbolt and move the evacuation line from the front of the manifold to the rear of the manifold (Figure 7). 4. Remove and replace the idler pulley with the pulley (F) supplied. 5. Attach bracket (P) and idler pulley back onto the vehicle using the existing bolts removed (Figure 8). Tighten securely. 6. Install the upper bracket (N) using the existing bolt previously removed (Figure 9). Leave loose at this time. 7. Install the back bracket (O) using the 8mm bolt (LL), lock washer (NN), and flat washer (MM) provided. NOTE: The flange faces to the rear of the vehicle. Leave loose at this time. Figure 7 Figure 8 Figure 9 4

5 III. Installing the Compressor 1. Remove and replace the alternator pulley with the new pulley (D) supplied. 2. Set the assembly unit in place. If the compressor still hits, remove the assembly and adjust the fender. 3. Insert the carriage bolt protruding from the compressor mounting plate through the top bracket. Attach using the flat washer (GG), lock washer (JJ), and nut (KK). Leave loose at this time. 4. Insert three carriage bolts (HH) through the bottom mounting holes and attach with flat washers (GG), lock washers (JJ), and nut (KK). Leave loose at this time (Figure 10). Figure Tighten all the support bracket mounting bolts at this time (i.e., alternator, idler pulley, etc.). 6. Install the new serpentine belt (with air (B), NAPA part # or without air (C), NAPA part # ). Route the belt per Figure 11. NOTE: Figure 11 is without air conditioning. 7. Be sure that the compressor and belt is fully aligned before securing the mounting hardware. If not aligned, unattach the belt and adjust the compressor as needed. Tighten all mounting and bracket hardware only when all is fully aligned. 8. Attach the negative cable, alternator wire, and clutch wire to the compressor using clamp (OO), bolt (FF), and flat washer (GG) supplied (Figure 12). Figure 11 IV. Reinstalling the Computer 1. Attach the computer bracket (K) to the fender using existing nuts previously removed (Figure 13). 2. Attach the computer to the bracket using bolt (PP), flat washer (RR), and nut (TT) supplied. Attach the wiring harness to the computer, if disconnected. Figure 12 Figure 13 5

6 V. Installing the Radiator Overflow Reservoir 1. Remove the two bolts on the ABS/brake bracket on the driver side fender (Figure 14) and attach the bracket (M) to the ABS brake bracket using existing bolts removed. 2. Loosely attach the reservoir (G) to the bracket using bolts (PP), flat washer (RR), and nuts (TT). Figure Mark the fender at the bottom using the bottom hole on the reservoir, center punch and drill a 1 /4" hole, being careful no to drill the tire. Reattach the reservoir in all three mounting locations. 4. Pull the overflow hose out of the clamps under the radiator. Reroute to the bottom of the reservoir. Cut and attach the hose using clamp (UU) provided. Fill the radiator half way with radiator fluid (Figure 14). VI. Checking the Belt Previously attached to vehicle 1. Attach the positive battery cable. 2. Check all hardware to be sure that it is secure. 3. Start the engine and observe the belt and pulley for alignment. NOTE: DO NOT ENGAGE CLUTCH YET. Adjust if necessary. VII. Installing the Filter 1. Using the provided thread sealant, assemble the bushing (Z) and relief valve (W) to the brass street tee (EE). Install a 1 /2" NPTM x 1/2" tube straight fitting (Y) to the tee (Figure 1). 2. With the arrow pointing in the direction of the flow, assemble the coelescing filter (H) to the brass tee assembly using the supplied sealant (Figure 1). Tighten securely. Figure Securely attach a 1 /2" NPTM x 1 /2" tube straight nipple (AI) to the port on the coelescing filter (Figure 1). 4. Loosely attach the filter bracket (Q) to the filter using the provided screws (SS). 5. Find a remote location on the frame or in the rear with enough clearance to install the filter assembly and use filter bracket as a template to mark mounting locations. Remove filter assembly and drill the mounting hole locations with a 1 /4" bit. 6. Remove the filter from the bracket and install the bracket using the self tapping bolts (QQ). Tighten securely (Figure 15). 7. Reattach the filter to the bracket and tighten screws securely (Figure 15). 6

7 VIII. Installing the Hose Assembly 1. Install the brass cross bracket (AA). Using the bracket (R) as a template, mark and drill the two 1 /4" mounting holes and attach using two bolts (PP) and two nuts (TT). 2. Attach the bushing (CC) and pressure switch (X) to one leg of the brass cross (AA) and plug (BB) to the other leg directly across from the pressure switch (Figures 1 and 16). 3. Attach the brass cross to the bracket using a 1 /2" NPTM x 1 /2" tube straight fitting (Y) on each side (Figures 1 and 16). 4. Install a 1 /2" NPTM x 1 /2" tube straight fitting (Y) to one end of the check valve (V) (Figure 1). Tighten securely. The check valve will be installed to the filter assembly. NOTE: The arrow points in the direction of the flow and the fitting goes onto the discharge end of the check valve. 5. Use the provided hose cutter (AG) to cut a length of ½" hose long enough to run from the cross assembly to the air fitting on the filter assembly. Do not attach at this time. 6. Being sure that the arrow on the check valve points in the direction of the flow, attach one end of the hose into the pushto-connect fitting on the check valve. Route the other end to the fitting on the cross assembly (Figure 1). 7. The open leg on the cross routes into a 1 /2" hose going to the existing air tank (Figure 1). To Check Valve Figure 16 Bushing Leader Hose Figure 17 To Air Tank Compressor Fitting Compressor 8. Using the thread sealant provided, assemble two of the brass couplings (DD) to both ends of the steel leader hose (J). Tighten securely (Figures 1 and 17). 9. Remove the caps to the discharge and supply ports on the top of the compressor. 10. Slide the O-rings (U) around the two sleeve inserts (T). Set the inserts into the port holes on top of the compressor. 11. Set the compressor fittings (S) over the inserts and loosely attach using the existing bolts removed. 12. Attach a coupling (DD) and filter (I) to the supply side (the side closest to the engine) using the provided sealant. Position the filter and tighten the compressor fitting bolt securely. 13. Firmly attach the steel leader hose to the remaining compressor fitting using the provided sealant (Figures 1 and 11). 14. Attach a 1 /2" NPTM x 1 /2" tube (Y) fitting to the opposite end of the leader hose. 15. Tighten the bolts on both compressor fittings securely. 16. Attach a length of hose (AF) from one end of the leader hose to the fitting on the relief valve assembly on the filter (Figure 1). IX. Checking the Oil Use a dipstick (AH) to check the oil depth. The depth must be between 1" and 1 1 /4" (Figure 13). If this is not done, the warranty will be void. 7

8 X. Wiring the Electrical System 1. The hot lead to the compressor is the black wire on the clutch. Cut off the fitting on the end of the black wire and using butt connector (ZZ), splice a length of the red wire (WW) to the black wire. Run red wire to spade terminal on the pressure switch. Attach a blue spade connector (AB) to the red wire and attach to one of the terminals on the pressure switch. 2. Splice the 20 amp fuse in the fuse box using the adapters provided into a hot keyed power source and run it to the other terminal on the pressure switch. 3. After all hardware has been secured and oil level is within range, the system is now ready to operate. See Figure 18 for a finished installation. 4. We recommend purchasing a spare belt to carry in the vehicle in case of a belt failure. 5. Check all fittings and air line connections for leaks with a solution of 1 /5 dish soap to 4 /5 water in a spray bottle. Important Warranty Information Figure If the compressor or engine is run without having oil in the compressor, then the warranty is void. 2. If the belt is misinstalled or the belt does not have the proper tension, then the warranty is void. 3. Failure to use included installation components properly voids the warranty. 4. Failure to check proper oil level and conditions will void the warranty. 5. This compressor must only be used in an air compressor application only, not an air conditioning application. No freon is required. 6. It is necessary to periodically check the filter for trapped oil. This needs to be performed three or four times a year. Failure to do so will result in reduced component life. 8

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10 10 EASYSTREET Thank you for purchasing Air Lift Products Mailing Address: Street Address: AIR LIFT COMPANY AIR LIFT COMPANY P.O. Box Snow Rd. Lansing, MI Lansing, MI Local Phone: (517) Fax: (517) For Technical Assistance call The Choice of the Professional Installer Printed in the USA